Gauge system for workpiece processing

ABSTRACT

Gauge system, including methods and apparatus, for positioning workpieces according to entered and/or calculated target dimensions and processing the workpieces with a tool to generate products having the target dimensions.

CROSS-REFERENCES TO PRIORITY APPLICATIONS

This application is a continuation of U.S. patent application Ser. No.12/797,581 filed Jun. 9, 2010, which claims priority from U.S.Provisional Patent Application Ser. No. 61/185,553, filed Jun. 9, 2009,and U.S. Provisional Patent Application Ser. No. 61/352,259, filed Jun.7, 2010, all of which are incorporated herein by reference in theirentirety for all purposes.

BACKGROUND

Computer-controlled positioning systems, also termed gauge systems, arecommonly used in manufacturing environments to position workpieces, suchas pieces of lumber, pipes, conduits, sheet metal, extrusions, or thelike, quickly and accurately relative to a processing tool, such as asaw. In stop-based gauge systems, a stop serves as a movable fence thatcontacts an end (or other surface) of a workpiece to establish adistance from the end to the processing tool. The stop can be drivenalong a linear axis (i.e., a measurement axis) to adjust the distance ofthe stop from the tool according to a target dimension for a product tobe formed by processing the workpiece with the tool, such as the lengthto be cut from a piece of lumber.

Stop-based, linear gauge systems can have various levels of complexity.More sophisticated versions automate control of the tool and use thestop as a pusher to drive movement of the workpiece toward the tool.These pusher-based systems can, for example, drive the end of aworkpiece toward the tool to multiple stopped positions at whichworkpiece processing is performed, to create multiple productsautomatically from a single workpiece. For example, pusher-based systemscan create a set of products of desired length automatically based on acut list. In contrast, simpler stop-based gauge systems combine (a) apassive stop that does not push the workpiece and (b) manual control ofthe tool. With these simpler systems, a user manually places a workpieceagainst the stop after the stop has ceased moving at a location definedby a target dimension, and then manually controls the tool to processthe workpiece.

Stop-based, linear gauge systems improve efficiency and accuracy,thereby saving time and money. Accordingly, many craftsmen, such asframers, finish carpenters, cabinet installers, and cabinetmakers, wouldbenefit from use of these gauge systems. However, these craftsmenfrequently do not work predominantly in a single facility, but insteadmay move frequently between different job sites. As a result, craftsmenoften opt not to invest in stop-based gauge systems because of thesesystems' perceived lack of portability, high cost, large size,complexity of use, lack of functionality, and difficulty to assemble andmaintain. Therefore, improved stop-based gauge systems are needed thatare more portable, less expensive, more compact, safer, less complex,more functional, and/or more user-friendly to assemble, operate,reconfigure, and/or service.

SUMMARY

The present disclosure provides a gauge system, including methods andapparatus, for positioning workpieces according to entered and/orcalculated target dimensions and processing the workpieces with a toolto generate products having the target dimensions.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic view of selected components of an exemplary gaugesystem for workpiece processing, with the system including a positioningapparatus in contact with an exemplary workpiece that has beenpositioned by the apparatus at a target distance from a tool, inaccordance with aspects of the present disclosure.

FIG. 2 is a schematic view of selected aspects of the gauge system ofFIG. 1, including a controller and peripheral devices that may be placedin communication with the controller, in accordance with aspects ofpresent disclosure.

FIG. 3 is a view of an exemplary saw-based embodiment of the gaugesystem of FIG. 1, in accordance with aspects of the present disclosure.

FIG. 4 is a view of a positioner, also termed a gauge or measuringapparatus, from the system of FIG. 3.

FIG. 5 is a fragmentary view of a rail module of the positioner of FIG.4, taken around a carriage and stop of the rail module.

FIG. 6 is a plan view of the positioner of FIG. 4, taken in the absenceof the brackets.

FIG. 7 is a front elevation view of the positioner of FIG. 4, taken inthe absence of the brackets.

FIG. 8 is a fragmentary plan view of the positioner of FIG. 4, takengenerally at “8” in FIG. 6 around a site of attachment of a power moduleto the rail module of the positioner.

FIG. 9 is a fragmentary sectional view of the positioner of FIG. 4,taken generally along line 9-9 of FIG. 8, with selected components notshown to simplify the presentation.

FIG. 10 is a cross-sectional view of the positioner of FIG. 4, takengenerally along line 10-10 of FIG. 7, with selected components not shownto simplify the presentation.

FIG. 11 is a fragmentary, longitudinal sectional view of selectedportions of the positioner of FIG. 4, taken generally along line 11-11of FIG. 7.

FIG. 12 is a cross-sectional view of the positioner of FIG. 4, takengenerally along line 12-12 of FIG. 11, with selected components notshown to simplify the presentation.

FIG. 13 is a cross-sectional view of the positioner of FIG. 4, takengenerally along line 13-13 of FIG. 11, with selected components notshown to simplify the presentation.

FIG. 14 is a back elevation view of the rail module of the positioner ofFIG. 4, with a carriage of the rail module repositioned relative to FIG.4.

FIG. 15 is a fragmentary back elevation view of the rail module of FIG.14, taken generally at “15” in FIG. 14.

FIG. 16 is a cross-sectional view of the positioner of FIG. 4, takengenerally along line 16-16 of FIG. 11, with selected components notshown to simplify the presentation.

FIG. 17 is an exploded, fragmentary view of an end region of the railmodule of the positioner of FIG. 4, taken from below and behind the railmodule, with a belt of the rail module not shown to simplify thepresentation.

FIG. 18 is a fragmentary, plan view of the positioner of FIG. 4, with astop of the positioner abutted with and axially positioning a workpiecehaving a miter-cut end, in accordance with aspects of the presentdisclosure.

FIG. 19 is a fragmentary, plan view of the positioner and workpiece ofFIG. 18, taken generally at “19” in FIG. 18.

FIG. 20 is a fragmentary, plan view of the positioner of FIG. 4, with astop of the positioner abutted with and establishing an axial positionfor a miter-cut workpiece, taken generally as in FIG. 19, but with thepositioner including a stop assembly of distinct structure from that ofFIG. 19.

FIG. 21 is a fragmentary view of the positioner of FIG. 4 equipped withanother exemplary stop assembly.

FIG. 22 is a fragmentary, plan view of the positioner of FIG. 21, with astop foot of the stop assembly abutted with a workpiece having amiter-cut end.

FIG. 23 is a fragmentary, cross-sectional view of the positioner of FIG.21, taken generally along line 23-23 of FIG. 21.

FIG. 24 is a fragmentary view of the positioner of FIGS. 21-23 equippedwith a different exemplary stop foot in the stop assembly, in accordancewith aspects of the present disclosure.

FIG. 25 is a top view of the positioner of FIG. 24 with the stop footabutted with a miter-cut end of a workpiece, in accordance with aspectsof the present disclosure.

FIG. 26 is an exploded view of a power module of the positioner of FIG.4.

FIG. 27 is a plan view of an exemplary keypad that may be included inthe power module of FIG. 26.

FIG. 28 is a side elevation view of an exemplary bracket assemblyutilized in the system of FIG. 3 to attach the rail module to a framebeam.

FIG. 29 is an exploded view of the bracket assembly of FIG. 28.

FIG. 30 is a side elevation view of another exemplary bracket assemblyattached to the rail module of the positioner of FIG. 4, in accordancewith aspects of present disclosure.

FIG. 31 is a fragmentary, partially exploded view of the bracketassembly and rail module of FIG. 30.

FIG. 32 is a flowchart illustrating an exemplary method of driving astop to a target position, which may be performed by a gauge system forworkpiece processing, in accordance with aspects of the presentdisclosure.

FIG. 33 is a flowchart illustrating an exemplary method of driving astop that may be performed on its own or may supplement or replaceportions of the method of FIG. 32, in accordance with aspects of thepresent disclosure.

FIG. 34 is a flowchart illustrating yet another exemplary method ofdriving a stop that may be performed on its own or may supplement orreplace portions of the method of FIG. 32, in accordance with aspects ofthe present disclosure.

FIG. 35 is a view of another exemplary saw-based embodiment of the gaugesystem of FIG. 1, in accordance with aspects of the present disclosure.

FIG. 36 is a fragmentary view of the saw system of FIG. 35, takengenerally around a power module attached to a rail module with drawlatches that each include a cam lever, in accordance with aspects of thepresent disclosure.

FIG. 37 is another fragmentary view of the saw system of FIG. 35, takenat elevation toward one of the latches after removal of an end cap froma beam of the rail module, with selected components not shown tosimplify the presentation.

FIG. 38A is an exploded view of either latch of FIG. 36, taken generallyfrom above and from an inner side of the latch that faces the powermodule.

FIG. 38B is another view of the latch of FIG. 38A, taken from the innerside of the latch after assembly of the latch and with the latch in anopen position.

FIG. 39 is a bottom view of the power module and latches of FIG. 36 withthe power module in a skewed position produced immediately after matingthe power module with the rail module and before closing the latches.

FIG. 40 is a bottom view of the power module and latches of FIG. 36,taken as in FIG. 39, but after rotating the power module into alignmentwith the beam of the rail module and after closing the latches.

FIG. 41 is a view of a bracket assembly from the system of FIG. 35,taken in isolation from other system components, in accordance withaspects of the present disclosure.

FIG. 42 is an exploded view of the bracket assembly of FIG. 41.

FIG. 43 is a side view of a rail mount of the bracket assembly of FIG.42 with the rail mount secured to a beam of the system of FIG. 35, inaccordance with aspects of present disclosure.

FIG. 44 is a view of an accessory support leg from the system of FIG.35, taken in isolation from other system components, in accordance withaspects of the present disclosure.

FIG. 45 is a fragmentary view of the saw system of FIG. 35, takengenerally around a stop foot abutted with a miter-cut end of a piece ofcrown molding, in accordance with aspects of present disclosure.

FIG. 46 is a sectional view of the system of FIG. 35, taken generallyalong line 46-46 of FIG. 45 through the crown molding and beam andtoward the stop foot, with selected components not shown to simplify thepresentation.

FIG. 47 is a top view of the stop foot and crown molding of FIG. 45.

FIG. 48 is a somewhat schematic, sectional view of a portion of a roomtaken through walls of the room toward its ceiling, with crown moldinginstalled to cover the interface between the walls and the ceiling.

FIG. 49 is a schematic view of an exemplary saw system including apositioner and a miter saw and illustrating how a distance from a stopto an origin of a measurement axis may be defined with respect tocutting paths and a pivot axis of the miter saw, in accordance withaspects of present disclosure.

FIG. 50 is another schematic view of the saw system of FIG. 49 with thesystem arranged to cut, without application of a miter offset by thepositioner, a piece of crown molding that will extend from an insidecorner to another inside corner in the room of FIG. 48, in accordancewith aspects of present disclosure.

FIG. 51 is yet another schematic view of the saw system of FIG. 49 withthe system arranged to cut, without application of a miter offset by thepositioner, a piece of crown molding that will extend from an insidecorner to an outside corner in the room of FIG. 48, in accordance withaspects of present disclosure.

FIG. 52 is still another schematic view of the saw system of FIG. 49with the system arranged to cut, after application of a miter offset bythe positioner, a piece of crown molding that will extend from anoutside corner to another outside corner in the room of FIG. 48, inaccordance with aspects of present disclosure.

FIG. 53 is a somewhat schematic view of the saw system of FIG. 49 withthe system arranged to cut, after application of a miter offset by thepositioner, a piece of crown molding that will extend from an outsidecorner to an inside corner in the room of FIG. 48, in accordance withaspects of present disclosure.

FIG. 54 is a somewhat schematic view of a doorway formed in a wall andwith the doorway framed with casing molding.

FIG. 55 is a schematic view of the saw system of FIG. 49 with the systemarranged to cut, after application of one miter offset by thepositioner, a piece of casing molding for the left jamb or left stile ofthe doorway of FIG. 54, in accordance with aspects of presentdisclosure.

FIG. 56 is another schematic view of the saw system of FIG. 49 with thesystem arranged to cut, after application of two miter offsets by thepositioner (one for each end), a piece of casing molding for the headeror lintel of the doorway of FIG. 54, in accordance with aspects ofpresent disclosure.

FIG. 57 is yet another schematic view of the saw system of FIG. 49 withthe system arranged to cut, after application of one miter offset by thepositioner, a piece of casing molding for the right jamb or right stileof the doorway of FIG. 54, in accordance with aspects of presentdisclosure.

DETAILED DESCRIPTION

The present disclosure provides a gauge system, including methods andapparatus, for positioning workpieces according to entered and/orcalculated target dimensions and processing the workpieces with a toolto generate products having the target dimensions. In exemplaryembodiments, the gauge system is more portable; more modular; easier toassemble, reconfigure, and/or service; simpler; and/or less expensive;among others, than gauge systems of the prior art.

The gauge system may be described as a workpiece processing system andmay utilize a tool having a site of action. The system may comprise arail, a stop connected to the rail and configured to be abutted withworkpieces, a drive assembly connected to the rail and capable ofdriving the stop back and forth (e.g., leftward and rightward) along therail to different separations from the site of action, and a controller.The controller may be programmed to receive a target dimension of aproduct to be generated from a workpiece with the tool. The controlleralso may be programmed to control the drive assembly such that the stopis driven to a target position spaced from the site of action accordingto the target dimension, thereby allowing the workpiece to be modifiedby the tool, with the workpiece disposed against the stop at the targetposition, to generate the product.

Cutting workpieces on a miter (i.e., obliquely) with a gauge system canbe complicated and problematic. The opposing sides of the product mayhave different lengths, only one or both ends of the product may bemiter-cut, and, if both ends are miter-cut, the cuts may be at leastgenerally parallel, convergent, or divergent. Furthermore, there may belimitations on which side of the workpiece should be placed against thesaw fence (e.g., when performing shear cuts in which the acute corner ofthe miter-cut end of a product is formed after the obtuse corner of thesame miter-cut end). Gauge systems of the prior art fail to provide anysolution to the problems associated with miter compensation or do somechanically, instead of with a controller. For example, a particulargauge system of the prior art provides a mechanical solution to mitercompensation by utilizing a stop that can be pivoted to a selectedangle, for abutment with a miter-cut end of a workpiece that has beenpre-cut at the same angle. However, the use of a pivotable stop is toocumbersome if the selected angle needs to be changed frequently, such aswhen square cuts and miter cuts are interspersed with one another. Also,the pivotable stop does not provide for any miter compensation at thesaw, which may be necessary if the saw is oriented to create a mitercut.

The present disclosure offers a controller-based solution to mitercompensation. The gauge system may be a saw system that cuts workpiecesto produce products, such as for use in miter joints. Accordingly, thetool may be a saw defining a cutting path. The stop may be driven backand forth along a measurement axis that intersects the cutting path todefine an origin. The controller may be programmed to receive a targetlength of a product to be generated from the workpiece. The controlleralso may be programmed to control operation of the drive assembly basedon the target length such that the stop is driven to an adjustedposition spaced from the origin by an adjusted length that modifies thetarget length with at least one miter offset, to compensate for a mitercut at one or both ends of the product. In some embodiments, a miter sawmay be in communication with the controller. The miter saw may sendsignals to the controller, with the signals corresponding to distinctselected angles of the miter saw. The controller may calculate therequired offset(s) for each angle and adjust target dimensionsaccordingly. Also, the controller may provide on-screen instructions(graphical and/or text) to the user for making cuts at the anglesselected. Furthermore, the gauge systems disclosed herein may permit allmiter cuts for a project to be made while feeding material in onedirection.

The gauge system of the present disclosure may include a rail module anda power module that can assembled and disconnected from one anotherquickly and easily, optionally without the use of tools. The rail modulemay include a beam that forms the rail and also may include a firstmember connected to the beam such that rotation of the first memberdrives the stop back and forth along the beam, to achieve differentseparations of the stop from the site of action of the tool. The powermodule may form at least part of the drive assembly and may include amotor and a second member rotated by operation of the motor. The powermodule may mate detachably with the rail module by fitting the first andsecond members together such that the operation of the motor transmitsmotive power to the stop. Accordingly, the rail module and the powermodule may be assembled with one another much more quickly and easilythan in prior art gauge systems, which may substantially enhance theportability of the gauge system (since the rail module and power modulecan be disconnected readily and transported while disconnected). Also,the modularity of the gauge system enhances its ability to bereconfigured for different users, tools, job sites, projects, etc.

Pulley-based gauge systems of the prior art mount pulleys on pulleycarriages, which are disposed in and attached to a beam. The spacing ofthe pulleys and thus tension on a connecting belt is controlled byadjusting the position of one or both pulley carriages along the beam.However, this approach suffers from a number of drawbacks: the belt maybe tensioned improperly or inconsistently, the gauge system may need tobe disassembled substantially to change the belt, the pulleys may driftin position over time, and/or the like.

In some embodiments, the gauge system disclosed herein avoids the needfor pulley carriages by mounting the pulleys in respective transversecavities formed in the beam. As a result, the pulleys may remain mountedand their spacing may remain constant even when the belt is changed. Thegauge system may incorporate a rail assembly that includes a beamforming the rail and that also includes a pair of pulleys and a beltthat couples rotation of the pulleys to one another. The beam mayinclude an exterior surface and a pair of cavities each extendingtransversely into the beam from the exterior surface. The pulleys may bemounted in the cavities. In some embodiments, pivot axes of the pulleysmay be coaxial with apertures formed in walls of the rail.

The gauge system also or alternatively may have a belt that is easier toaccess, tension, and/or replace. The gauge system of the presentdisclosure may include a rail assembly, which may incorporate a beamforming the rail and also may be equipped with a pair of pulleys and abelt that couples rotation of the pulleys to one another. The belt mayextend to a pair of ends. The rail assembly may include a belt linkagethat secures the pair of ends adjacent one another to form a closed looparound the pulleys. The belt linkage may be adjustable to change aspacing of the ends relative to each other while the ends remainsecured, thereby permitting changes to a tension of the belt via itsends. As a result, in some embodiments of the gauge system, the belt maybe replaced and/or its tension adjusted without removing the pulleysfrom the beam and/or without changing their spacing from one another,which simplifies construction and belt maintenance. In contrast,pulley-based gauge systems of the prior art involve translationalmovement and/or disconnection of the pulleys from a beam in order topermit belt tensioning and/or belt replacement.

Gauge systems of the prior art fail to throttle power intelligently, ifat all. In particular, in these prior art systems, when motion of thestop is blocked or hampered, greater and greater amounts of power aresupplied to the motor in an attempt to drive the stop anyway. As aresult the power supplied to the motor can spike quickly, which maycause the controller to lose data and/or which may case sensor data fromthe rotary encoder to become unreliable, thereby requiring a restart ofthe controller. Controller restarts waste time and can be very annoyingto the user. Also, power spikes can damage the motor. Furthermore,forcing motion of the stop with large amounts of power can injure auser, such as when the user's hand gets caught in the stop.

In some embodiments, the gauge system of the present disclosure may becapable of performing power throttling, to minimize the generation ofpower spikes and power overloads without compromising the ability of themotor to efficiently drive the stop. The drive assembly of the gaugesystem may include a motor. The controller may be programmed to restrictamounts of power supplied to the motor according to a predefined limit.The predefined limit may increase with a speed of the motor, therebyreducing or eliminating generation of power spikes when motion of thestop is blocked or hampered. The gauge system thus may provide powerthrottling that functions as a software-based “spring.” The powerthrottling may enable use of travel barriers and may reduce motor wearand failure, improve hand safety (such as if a hand gets jammed betweenthe stop and the rail), and/or reduce power overloads, among others.

Gauge systems of the prior art avoid use of travel barriers (e.g., hardstops) to restrict stop movement because travel barriers can cause powerspikes and power overloads when a carriage and/or stop encounters atravel barrier. Instead, prior art gauge systems utilize end sensors tosense when the stop has neared an end of its range of travel, so thatthe stop can be halted before a physical barrier is contacted by thestop and/or its carriage. However, end sensors have numerousdisadvantages, including cost, difficulty to install and service, andinaccuracy in precisely defining stop position.

The gauge system may use travel barriers. The travel barriers may beused to facilitate placing the stop at a known position, to determine avalue for a range of travel of the stop based on a pre-set scale factor,to determine a position for each end of the stop's range of travel,and/or to calculate a scale factor that correlates rotation of the motorto linear travel of the stop. The gauge system may incorporate a railassembly that includes the rail, a carriage, and at least one travelbarrier. The stop may be supported by the carriage and may have a rangeof travel along the rail. At least one end of the range of travel may bedetermined by contact of the carriage with the travel barrier. Thecontroller may be programmed to drive the stop until movement of thestop is halted by the contact of the carriage with the travel barrier,to define the current location of the stop, thereby placing the stop ata home position (i.e., homing the stop).

Gauge systems of the prior art permit operative connection of a motor toonly one end region of a rail. Accordingly, in these systems, theleft/right position of the motor either is fixed or can be changed bydisconnecting the rail from its mounted position and flipping the railover lengthwise. As a result, moving the motor from left to right iscomplicated and may require substantial disassembly of the system andre-tensioning of the belt.

The gauge system of the present disclosure may permit more flexibilityand/or ease in selecting and changing motor position. The rail may haveopposing end regions. The drive assembly may include a motor thatsupplies motive power to the stop. The motor may be operativelyconnectable to the rail with the motor disposed adjacent either opposingend region to couple operation of the motor to driven motion of the stopback and forth along the rail. In some embodiments, the motor may beconnected adjacent each end region without changing the orientation ofthe rail. In some embodiments, the motor may be operatively coupled toat least one pulley mounted to the rail while the pulley remains mountedto the rail. An ability to connect a motor to either end of the railgreatly improves portability.

Gauge systems of the prior art place the carriage at least mostly insidethe rail. This placement substantially encloses the travel path of thecarriage, which avoids inadvertent obstruction of carriage movement,thereby minimizing power spikes, power overloads, and injury. However,placing the carriage inside the rail makes assembly, service, and repairof the carriage more difficult and time consuming.

The gauge system of the present disclosure may position the carriageexternally to the rail, and thus more conveniently for assembly,service, and repair, relative to an internal carriage. The gauge systemmay include a carriage that supports the stop. The rail may include abeam that supports the carriage and forms an external track. Thecarriage may be driven along the beam guided by the external track. Insome embodiments, the carriage may be disposed externally on the rail toslide along an external way formed outside the rail, rather than insidethe rail. The carriage may include one or more set screws to removeplay.

Gauge systems of the prior art design the motor and controller asseparate modules. With this approach, the controller can be situatedconveniently for the user, such as above the rail, while the motor canbe situated out of the way of the user, such as behind the rail. Also,the controller can be moved along the rail to accommodate different toolpositions, target lengths, or user preferences, while the motor is keptat the same site adjacent the rail (since the user does not need to havecontinual access to the motor). Moreover, both the motor and thecontroller can be replaced or serviced individually. Furthermore, thecontroller can be readily shielded, by intervening space, from heat andvibration generated by the motor. However, keeping the motor andcontroller separate makes the gauge system less portable and moredifficult to reconfigure. The gauge system of the present disclosure mayplace the motor and controller in the same module. The system mayinclude a motor box that includes a motor that forms a portion of thedrive assembly and also includes the controller. In some embodiments,the gauge system may include a power module that incorporates the motor,the controller, and a user interface, which improves the portability andthe ease of assembly and disassembly of the system. The integrated powermodule may be configured to mate with a rail module that includes therail and a drive linkage of the drive assembly.

The gauge system of the present disclosure may adapt to different stylesof entering target dimensions. The controller may be programmed toreceive target dimensions entered in either decimal format or fractionalformat by a user and to display the target dimensions according to theformat in which the target dimensions were entered.

These and other aspects of the present disclosure are included in thefollowing sections: (I) system overview, (II) an exemplary embodiment ofa saw-based gauge system, (III) an exemplary embodiment of a positioningapparatus, (IV) exemplary bracket assemblies, (V) exemplary control andoperation of a positioning apparatus, and (VI) examples.

I. SYSTEM OVERVIEW

FIG. 1 shows an exemplary gauge system 50 for positioning and processingof workpieces. The gauge system may include a stop 52 and a tool 54 thatare connected to one another and/or supported by a frame assembly 56.The frame assembly may incorporate a base frame 58, a rail 60 (which maybe part of a rail assembly), and, optionally, one or more bracketassemblies 62 that connect rail 60 to base frame 58. Rail 60 may beelongate and linear and also or alternatively may be described as alongitudinal fence, a frame, a frame member, a linear rail, a beam, alinear beam, a guide, or a linear guide.

Stop 52, which also or alternatively may be described as a datumstructure or a transverse fence, may be driven back and forth (e.g.,leftward and rightward), indicated at 64, along the rail and parallel toa measurement axis 66 (also termed a positioning axis) by a driveassembly 68 controlled by a controller 70. In some embodiments,measurement axis 66 may be at least substantially parallel to alongitudinal axis 72 defined by the rail, with the rail extendingparallel to measurement axis 66. Measurement axis 68 generally is alinear axis. In any event, the stop, and particularly a datum surface 74thereof, may be driven by drive assembly 68 to a target distance ortarget dimension 76 (also termed a set point) from a processing site orsite of action 78 for tool 54. More particularly, the tool may define anorigin 79 of measurement axis 66 where the measurement axis intersectsthe processing site and the stop may be driven to a target positionspaced from the origin along the measurement axis by the targetdimension. The target dimension may be for a product to be formed from aworkpiece 80 by action of the tool and/or may be adjusted to compensatefor a miter offset, among others.

Target dimensions (or set points) generally include any datacorresponding to one or more target distances of the stop to a landmark,such as a processing site or site of action for a tool. Target dataand/or signals may correspond to one or more values entered via one ormore input/output devices and/or calculated/converted by a controllerbased on entered data/set point signals. The target dimensions may beentered, received, and/or calculated as a list of values, such as a cutlist defining the values of a characteristic target dimension (e.g., thetarget lengths) of a set of cut products.

A target dimension may be any characteristic dimension of a product tobe generated from a workpiece. The characteristic dimension may, forexample, be any perimeter dimension measured parallel to one of the mainaxes of a workpiece, such as a target length or target width, amongothers. The target length thus may be a target longitudinal dimension,such as for a square-cut product. Alternatively, for a miter-cutproduct, the target length may be a shortest or “short point” targetlongitudinal dimension (i.e., a short-point target length) or a longestor “long point” target longitudinal dimension (i.e., a long-point targetlength). In some embodiments, the gauge system may receive a short-pointtarget length and then move the stop according to a long-point targetlength calculated using the short-point target length, and, optionally,a width of the workpiece. Alternatively, the gauge system may receive along-point target length and then move the stop according to ashort-point target length calculated using the long-point target length.In some embodiments, where the tool (such as a drill) does not changethe characteristic perimeter dimensions of the workpiece, the targetdimension for a product may be measured from an end or side surface ofthe product to a site on the product where the product is modified(e.g., bored) by the tool.

A miter, as used herein, is an oblique surface of a workpiece. A mitermay be formed by performing a miter cut (an oblique cut) through theworkpiece, to form an oblique surface on the workpiece. A workpiece orproduct with at least one miter may be called a mitered workpiece orproduct. The miter may be formed at a miter angle, which is the angle bywhich the oblique surface is tilted from orthogonal or parallel to oneor more characteristic axes (i.e., longitudinal or traverse axes) of theworkpiece. A miter offset may be any dimensional adjustment valuenecessitated by a miter present on the workpiece or to be formed on aproduct thereof. Incorporation of a miter offset into a dimensiongenerally means that the miter offset is used to modify the dimension,such as adding the miter offset to, or subtracting the miter offsetfrom, the dimension.

A width, as used herein, is a characteristic transverse dimension of anarticle. The width, for example, may be the larger one or the smallerone of the two characteristic transverse dimensions of a rectangularworkpiece. In some embodiments, the width may be the largercharacteristic transverse dimension, such as for miter compensation withcasing molding. In some embodiments, the width may be the smallercharacteristic transverse dimension, such as for miter compensation withbaseboard molding. In some embodiments, the width may be an effectivewidth for crown molding supported at its spring angle.

Measured aspects, such as dimensions, lengths, widths, angles (ortangents thereof), positions, distances, speeds, and so on, used hereingenerally have values. For example, a user may enter into a controller avalue for a target length. However, the use of “value” has been omittedin most cases herein, for the sake of brevity and because the term“value” is understood from the context without a need to recite the termexplicitly. For example, the phrase “a user may enter a value for atarget length” is generally shortened herein to “a user may enter atarget length,” with equivalent meaning.

The stop may be moved along the measurement axis with respect to therail and/or frame assembly, which may remain at least substantiallystationary during stop movement. The stop may be driven to a targetposition corresponding to the target dimension, where movement of thestop ceases. The stop may be held at the target position to resist stopmovement, such as by operation of the drive assembly and/or an accessorydevice, such as a clamp, among others. Workpiece 80 may be processed bythe tool while abutted with the stop and while the stop is held at thetarget position. The stop held at the target position may be describedas being at least substantially immobile, stationary, or fixed. Theworkpiece may be placed against the stop before or after the stop ismoved to the target position.

Stop 52 may be any datum structure that serves as a basis formeasurement. The stop may be described as a fence, a pusher, a foot, orthe like. Generally, the stop provides a contact surface for abutmentwith a workpiece, with the contact providing a datum from which tomeasure the linear distance to an origin of the measurement axis, whichcorresponds to the linear distance to a site of action for the tool.

Gauge system 50 may support a workpiece 80 and situate the workpiecewith respect to three orthogonal axes using stop 52 and frame assembly56. Stop 52 defines the location of the workpiece along measurement axis66 and frame assembly 56 may define the location of the workpiece alonga vertical axis and a transverse axis 82, which each extend transverselyto measurement axis 66. Measurement axis 66 and transverse axis 82 mayhave any suitable orientation with respect to a user of the gaugesystem. In an exemplary configuration, the measurement axis extendsgenerally leftward and rightward and the transverse axis extendsgenerally forward and rearward with respect to the user.

The workpiece may be supported by frame assembly 56, generally with alongitudinal axis 84 of the workpiece disposed horizontally. Support forthe workpiece may be provided by any suitable portion of the frameassembly (and/or stop), such as base frame 58, rail 60, brackets 62, ora combination thereof, to define an elevation of the workpiece above thefloor/ground along a z-axis (vertical axis). The frame assembly (i.e.,frame 58, rail 60, and/or one or more brackets 62) may support workpiece80, indicated schematically at 86, by contact with a surface of theworkpiece, generally a lower or bottom surface 88 (i.e., an underside)thereof. The workpiece may be aligned with the measurement axis: acharacteristic axis of the workpiece (such as longitudinal axis 84) maybe oriented parallel to measurement axis 66 by contact of anotherworkpiece surface (e.g., a front/rear surface 90) with the frameassembly (frame 58, rail 60, and/or bracket(s) 62). In some embodiments,rail 60 abuts the workpiece to define a position of the workpiece alongtransverse axis 82, thereby acting as a longitudinal fence. A fence isany wall or barrier against which a workpiece is placed to position theworkpiece for processing with a tool.

Frame 58 of the frame assembly may have any suitable structure, such asa stand, a table, a base, a bench, or a combination thereof. In someembodiments, frame 58 may be self-supporting and/or may include legsand/or feet to support the frame assembly on a generally horizontalsurface, such as a floor and/or the ground. In some embodiments, frame58 may provide supportive contact for the workpiece using a discretetool frame that is connected to a base frame (e.g., see FIG. 3).

Workpiece 80 may be positioned with the aid of stop 52 at a targetposition spaced according to the target dimension from the site ofaction of tool 54 along measurement axis 66. The stop may be driven tothe target position before or after the workpiece is contacted with thestop. If the stop is driven to the target position before workpiececontact, the workpiece may be contacted with the stop manually (orautomatically) by moving the workpiece with respect to the stop.Alternatively, if the stop is driven to the target position afterworkpiece contact, the stop may function as a pusher that drivesmovement of the workpiece. In any event, a workpiece datum 92 (e.g., anend surface 94) may be abutted with stop 52 at stop datum 74, to disposethe workpiece for processing by the tool at a target distance or targetdimension 76 from end surface 94 (or other datum surface) of theworkpiece. When disposed for processing by the tool, the workpiece mayextend across the site of action of the tool, such as extending across acutting path defined by a saw as the tool.

The systems of the present disclosure may position and processworkpieces. A workpiece, as used herein, is any piece of material thatwill be, or is being, positioned and/or processed by a gauge system. Atool of the gauge system thus may process the raw form of the workpiece,a partially processed form of the workpiece (such as a workpiece cutinto smaller pieces or segments (a segmented form of the workpiece)and/or modified otherwise), or both. A processed form of a workpiece, asused herein, is termed a workpiece product or a product.

A workpiece may have any suitable composition. Workpieces thus may beformed of wood, metal, plastic, fabric, cardboard, paper, glass,ceramic, or a combination thereof, among others. The composition may begenerally uniform or may vary in different regions of a workpiece.Exemplary workpieces are wood products, for example, pieces of lumber,such as pieces of stock. Other exemplary workpieces are metal sheets,pipes, or bars.

A workpiece may have any suitable shape and size. Generally, theworkpiece is elongate. However, in some embodiments, the workpiece maynot be elongate and/or may not be oriented with the long axis of theworkpiece parallel to the measurement axis. The workpiece may have anysuitable length. Exemplary lengths are based on available lengths ofstock pieces, such as stock lumber of about two feet to twenty feet inlength, for the purpose of illustration.

A workpiece may be of generic stock or may be pre-processed according toa particular application, before processing in a gauge system. Forexample, the workpiece may be a standard or pre-cut piece of raw lumber.Alternatively, the workpiece, before processing by the gauge system, mayinclude one or more holes, grooves, ridges, surface coatings, markings,etc., created, for example, based on desired features of products to beformed by the gauge system.

Any suitable tool 54 (or two or more tools) may be used to process theworkpiece. Processing the workpiece with a tool, as used herein,includes any structural modification of workpiece by the tool, such asby adding material to the workpiece (e.g., printing, painting,fastening, etc.), removing material from the workpiece (e.g., cutting orboring), reshaping the workpiece without substantially removing oradding material (e.g., bending, forming, stamping, etc.), or anycombination thereof. The tool may be driven manually or may be a powertool (e.g., an electrical power tool). Furthermore, the tool may becontrolled manually, such as after manual positioning of the workpieceagainst the stop. Alternatively, the tool may be controlledautomatically by a tool controller 96 that determines when and/or howthe tool processes the workpiece. (Controller 96 is shown in phantomoutline to improve clarity.) Tool controller 96 may be in communicationwith stop controller 70, or motion/operation of both the stop and thetool may be under control of the same controller. Automatic control oftool 54 with a controller may be more suitable when stop 52 isconfigured as a pusher that drives workpiece movement. Exemplary tools54 include saws (e.g., chop saws (also termed miter saws), table saws,radial arm saws, panel saws, cold saws, hand-driven saws, etc.), drills,shearers, routers, notchers, riveters, printers, sprayers, insertiontools (such as to drive fasteners), assemblers, or any combinationthereof, among others. The tool may provide a fixed processing site withrespect to the frame assembly along the measurement axis or theprocessing site may be adjustable with respect to this axis.Alternatively, or in addition, the tool may provide a processing sitethat is fixed or movable with respect to the frame assembly along anaxis parallel to transverse axis 82 and/or along a z-axis. Furthermore,the tool may provide a generally planar processing site (e.g., a planeof cutting), which may have an adjustable angle about an axis parallelto transverse axis 82 and/or about a z-axis. In some examples, the toolmay be a saw defining a cutting path. The saw may be a miter saw that isadjustable to orient the cutting path about the origin of themeasurement axis.

Drive assembly 68 provides the motion or motive power that drives stop52 along the rail. The rail and stop, with or without the driveassembly, may be described as a linear actuator. The drive assembly mayinclude a motor assembly 98 with at least one motor 100 coupled to adrive linkage 102. The motor may receive drive signals from controller70, to control operation of the motor, such as controlling the motor's(rotary) direction of rotation, position, speed, and/or acceleration.Any suitable type of motor may be used, for example, AC or DC, single ormultiphase, induction, servo, synchronous, universal, and/or gearmotors, among others. The motor may rotary or linear. In exemplaryembodiments, the motor may be a DC servomotor.

Drive linkage 102 couples the stop movably to the rail and generallyincludes any portion or all of a mechanism that transmits motion fromthe motor/motor assembly to the stop. Drive linkages may, for example,include pulleys, gears, belts, screws, fixed connectors, or the like, inany suitable combination. Exemplary drive linkages convert rotary motionof the motor into linear motion of the stop, and thus may include abelt-and-pulley mechanism, a screw drive, and/or a worm drive, amongothers. Other exemplary drive linkages couple linear motion of the motor(a linear motor) to linear motion of the stop. Thus, the motor may be acarriage that drives itself (and a connected stop) back and forth alongthe rail and measurement axis.

Drive assembly 68, at least one sensor 104, and controller 70 may form afeedback loop or mechanism 106 through which the controller directs thestop to set points (or target positions). Sensor 104 may be a positionsensor that is operatively coupled to drive assembly 68, to sense aposition of the drive assembly, which can be correlated with atranslational position of the stop along the measurement axis. Thesensor may communicate sensed position signals to the controller, andthe controller may utilize the position signals to determine drivesignals to communicate to the motor assembly. For example, thecontroller may compare the current position of the drive assembly (andparticularly a moving component thereof) to a set point, which may be afixed set point or a time-dependent dynamic set point (see FIG. 32), todetermine a difference (“an error”) between the current position and theset point.

The controller may calculate drive signals for sending to the motorassembly based on any suitable aspect or aspects of the error, such asthe magnitude of the error (proportional control; “P”), a sum of theerror over time (integrative control, “I”), a change in the error overtime (derivative control; “D”), or any combination thereof, amongothers. Accordingly, the feedback loop may operate under PID, P, PI, PD,etc. control by the controller. Exemplary feedback loops include a PIDposition loop, a cascaded position/velocity loop, or a PID loop withvelocity and/or acceleration feedforward, among others. In the someembodiments, the feedback loop may use a target position from a look-uptable and compare it with the actual position.

In exemplary embodiments, sensor 104 may be a rotary encoder, which maybe configured to sense a position of motor assembly 98, such as a rotaryposition of a rotary component of the motor assembly (e.g., a shaft, agear, a pulley, or a wheel thereof, among others) achieved by rotationof the rotary component. The rotary position may be compared with afixed or dynamic rotary set point (corresponding to a fixed or dynamiclinear set point), to determine a drive signal to send to the motorassembly and particularly the motor thereof.

Controller 70 may be connected and/or connectable to any other suitabledevices and/or sources. For example, the controller may be incommunication with one or more input/output devices 108, which maycommunicate data (signals) to and/or receive data (signals) from thecontroller. Also, controller 70 (and/or tool controller 96) may beconnected to a power supply 110, which may supply AC power or DC power.Accordingly, gauge system 50 may run on line power, such as by pluggingthe system into an electrical outlet, and/or may run on power from aportable DC power source, such as at least one battery.

Components of gauge system 50 may form a positioning apparatus 112,which may be a discrete unit that can be connected to various tools 54and/or frames 58, such as via brackets 62. Positioning apparatus 112 mayinclude stop 52, rail 60, drive assembly 68, controller 70, and sensor104, or any combination thereof. Apparatus 112 further may include oneor more brackets 62, additional sensors 104, input/output devices 108, apower supply 110, or any combination thereof. In some embodiments, rail60, at least a portion of drive linkage 102, and, optionally, stop 52,may be provided in a discrete unit 114, which may be described as a railmodule, a measuring bar, a rail unit, a rail assembly, a beam unit, or abar unit, among others.

FIG. 2 shows a schematic view of selected aspects of gauge system 50,particularly controller 70 and associated devices 130 (also termedperipherals or peripheral devices), namely, motor assembly 98, at leastone sensor 104, and input/output devices 108, which may be disposed incommunication with the controller via one or more ports 132 of thecontroller using any suitable communication mechanism. For example, anyperipheral 130 may be connected and/or connectable to a port 132 byelectrical conduction, that is, by a “wired” connection (also termed ahard connection), for example, with a plug, socket, and cable.Alternatively, or in addition, any peripheral 130 may be connectedand/or connectable to port 132 by a “wireless” connection, that is,without interconnection by an electrical conductor. Wireless connectionmay rely on communication by transmission through air of data, which maybe encoded by light (electromagnetic waves, e.g., infrared light, radiowaves, microwaves, visible light, or the like) or sonic energy, amongothers. Any suitable wireless implementation, device, and standard maybe used, such as to provide short-range, point-to-point communicationwith controller 70 or longer range communication with the controllerover a wireless network.

Controller 70 may be described as a computer or a computing device. Thecontroller may include a processor 134 (which may be described as amicroprocessor and/or a digital processor), a clock 136, memory 138, andan amplifier or drive chip 140, among others. Ports 132, clock 136,memory 138, and amplifier 140 may be connected to processor 134 and/orto one another by busses 142. In some embodiments, the controller may bea hand-held device, such as a person digital assistant, a mobile phone,or the like, and may communicate with the drive assembly wirelessly.

Memory 138 may have any suitable structure and may store any suitableinformation. The memory may be readable/writable, read-only, or acombination thereof. Memory 138 may store drive data 144 andinstructions 146, among others. The instructions, which may be describedas software, generally operate on the drive data to determine suitableoutput signals to communicate to motor 100 and other peripherals 130.Drive data 144 may include and/or correspond to one or more fixed and/ordynamic set points or target dimensions, target speed profiles, apredefined range of travel for a carriage/stop, travel endpointpositions, a motion log, at least one scale factor, calibration data,left/right tool position, or any combination thereof, among others.Instructions 146 may include algorithms, such as a feedback algorithm, ascale algorithm, a calibration algorithm, a power throttle algorithm, amiter algorithm, or any combination thereof, among others. Furtheraspects of drive data 144 and instructions 146 are described elsewherein the present disclosure, such as in Sections II, III, V, and VI.

The present disclosure also provides a storage medium encoded with amachine readable computer program code, with the code includinginstructions for causing a controller to implement any of the methodsdisclosed herein. The storage medium may, for example, be memory 138 ofcontroller 70 and/or peripheral memory.

Amplifier 140 may be configured to amplify a drive signal generated bythe controller using drive data 144 and instructions 146 before thedrive signal is communicated to motor 100. Accordingly, amplifier 140may include a digital to analog converter, to convert a digital drivesignal to an analog drive signal. The amplifier also or alternativelymay increase the amplitude of the drive signal, by applying a transferfunction to the drive signal, to increase its voltage, current, or both.Alternatively, or in addition, amplifier 140 may operate by pulse widthmodulation to send pulses of electrical power to the motor, with thewidth of each pulse corresponding to the magnitude of a digital drivesignal.

Sensor 104 may include one or more sensors, with each sensor measuringany suitable aspect of the positioning apparatus, such as an aspect ofmotor assembly 98 and/or motor 100, drive linkage 102, stop 52, orcontroller 70, among others. Exemplary sensors 104 include a positionsensor 148 (e.g., a rotary encoder or a linear encoder (e.g., endsensors disposed in/on the rail), among others), a temperature sensor150, and/or an electrical sensor 152. The temperature sensor may becoupled to the motor assembly and may be configured to measure atemperature of the motor assembly and particularly the motor. Theelectrical sensor may be disposed in a circuit connecting the controllerto the motor and may be configured to measure an electrical parameter ofthe electrical power supplied to the motor, such as the current,resistance, and/or voltage. The sensed temperature and/or electricalparameter may be communicated to the controller at time intervals todetermine whether the amount of electrical power supplied to the motorshould be reduced. This approach may be utilized to identify situationswhere the motor is working too hard and using too much power, to avoiddamage to the motor, to avoid power spikes that may cause the controllerto require a re-start, and/or to improve the safety of the gauge system.Further aspects of the use of sensor measurements to throttle powersupplied to the motor are described elsewhere in the present disclosure,such as in Sections V and VI.

Controller 70 may be connected and/or connectable to any suitablecombination of peripherals 130 to form a user interface 154. The userinterface may, for example, include input controls 155, a display 156, aprinter 158, a measuring device 160, a calculator 162, and peripheralmemory 164.

Input controls 155 may include any electronic device or combination ofelectronic devices configured to permit a user to input data tocontroller 70. Exemplary input controls may include a keypad, akeyboard, a touch screen, a microphone (for speech recognition), amouse, a joystick, or the like. Further aspects of user input controlsthat may be suitable are described elsewhere in the present disclosure,such as in Section III.

Display 156 may include any electronic device or combination ofelectronic devices configured to present images transiently, that is,without producing a permanent record. Exemplary displays may includeliquid crystal display (LCD), light-emitting diode (LED), cathode raytube (CRT), electroluminescence, field emission, digital lightprocessing, and plasma displays, among others. In exemplary embodiments,the display is an LCD display that displays only one line of characters,such as a maximum of 20 or less characters (numbers, letters, and/orother symbols).

Printer 158 may include any suitable type of printer, such as an inkjetprinter, a laser printer, a dot matrix printer, or the like. The printermay be configured to print any suitable data on any suitable printmedium. In exemplary embodiments, the printer may be a label printer.The labels printed by the label printer may present information about aprocessed product, such as its length, its type, a part number, itscomposition/material, the processing site (e.g., city, company, etc.),the time, the date, the project, or any combination thereof, amongothers. The labels may be self-adhesive and may be printed on anassembly of a front layer with an adhesive surface and a non-adhesiveback layer that covers the adhesive surface. In some examples, theprinter may have a wireless connection to the controller and maycommunicate via infrared or radio wave signals.

Peripheral measuring device 160 may include any peripheral deviceconfigured to measure one or more linear and/or nonlinear dimensions,and to encode the measured dimensions as signals for communication tothe controller. Measuring device 160 generally is equipped with memoryto store data corresponding to at least one or a plurality ofmeasurements. Exemplary measuring devices may include a tape measure(e.g., a digital tape measure), calipers, an optical measuring device(e.g., a laser-based device), any combination thereof, or the like. Auser may capture one or a series of measurements that are stored in thedevice, for example, as a cut list. The device may be used remotely fromthe positioning apparatus and then may be placed in proximity to thecontroller to download the measurements through either a wired orwireless connection to the controller, as a batch of measurements or oneat a time. Alternatively, the measurements may be sent from themeasuring device to the positioner, either one at a time as measured oras a batch, while the user is measuring remotely. Further aspects ofperipheral measuring devices are described in U.S. Provisional PatentApplication Ser. No. 61/185,553, filed Jun. 9, 2009, which isincorporated herein by reference.

Calculator 162 may include any device configured to perform calculationson data. The calculator may or may not be hand-held and may be poweredby one or more batteries or by line power. The data may be inputted by auser via a user interface of the calculator, may be received from thecontroller (e.g., after input via user interface 154, with or withoutsubsequent data processing by the controller), or may be received fromperipheral measuring device 160 via a wired or wireless connection. Insome embodiments, calculator 162 may be integral to controller 70 ormeasuring device 160.

Any suitable calculations may be performed by calculator 162, such ascalculations that are common in construction, manufacturing, or thelike. Calculator 162 may be described as a construction calculator.Exemplary calculations performed by the calculator may include at leastone of or any combination of (1) unit conversion (e.g., yards, feet, andinches to metric and vice versa), (2) area and volume calculations fromdimensions, and vice versa, (3) conversion of degree, minute, secondsvalues to decimal degrees, and vice versa, (4) trigonometriccalculations, (5) determination of values for stair parameters, such asthe run and rise, tread width, stringer length, incline angle, etc., (6)calculation of roof pitches, (7) board feet calculations, (8)calculation of the layout of studs for a wall, (9) calculation of headerdimensions for a given opening, (10) calculation of the layout of dropceilings for T-bar cutting, (11) calculation of hanger dimensions basedon roof pitch to allow for flat ceiling installation, (12) calculationof areas, diameters, and circumference of circles and arcs, (13)calculation of rafter dimensions, including common rafters, regular andirregular hips, valleys, and jacks, (14) calculation of rebar lengthbased on the length of each leg and the bend diameter, and (15)calculation of miter angles for retrofitting an opening that is notsquare, based on the perimeter lengths of the opening and the diagonallengths of the opening.

Any dimension resulting from any of the calculations performed by thecalculator may be sent to the controller as a set point distance(s) ortarget dimension, which may be executed by the controller, automaticallyor after request by a user, to drive stop movement according to the setpoint distance(s) or target dimension. Alternatively, or in addition,any dimension resulting from any of the calculations performed by aperipheral calculator may be sent to the controller for furthercalculations by an integral calculator of the controller.

Peripheral memory 164 may include any memory device that is or can beplaced in communication with controller 70. The memory device may permitupload to or download from the controller of any suitable data.Exemplary data that may be uploaded include new or revised instructions146 for the controller, which may confer new or revised functionality tothe controller. Other exemplary data may include a list of targetdimensions, such as a cut list. Exemplary data that may be downloadedinclude drive data, such as stored set points or target dimensions, ascale factor, one or more motion logs, etc. Peripheral memory 164 may beprovided by any suitable device such as a PDA (person digitalassistant), a mobile telephone, a flash drive, or the like. Theperipheral memory may communicate with the controller of the gaugesystem by a wired or wireless connection.

A motion log generally includes any data corresponding to positions ofthe stop with respect to time. The data may correspond to a currentposition of the stop, one or more preceding positions of the stopmeasured at one or more earlier time points, and/or one or moresucceeding target positions of the stop after the current position atone or more later time points. Data from the motion log may allowcalculations corresponding to an aspect of the motor and/or stop, suchas its speed, acceleration, change in acceleration, and/or an error ordifference between its current and target positions.

II. EXEMPLARY EMBODIMENT OF A SAW-BASED GAUGE SYSTEM

FIG. 3 shows an exemplary embodiment 180 of gauge system 50 (see FIGS. 1and 2) including a saw as the processing tool. Any combination of thedevices, components, and features of system embodiment 180 (hereinafter,saw system 180) may be combined with any of the devices, components, andfeatures shown and/or described elsewhere in the present disclosure.

Saw system 180 may include a frame 56 in the form of a stand 182, onwhich is mounted a positioner 184 and a saw machine, namely, a chop saw186. Positioner 184, which is illustrated using a greater line weight todistinguish it from the stand and chop saw, is an embodiment ofpositioning apparatus 112; chop saw 186 is an embodiment of tool 54 (seeFIG. 1). The embodiments of stand 182 and chop saw 186 shown here aremanufactured by DeWalt Industrial Tool Company and thus may be describedas a DeWalt® saw stand and a DeWalt® chop saw.

Stand 182 may include a central body or beam 188 connected to legs 190that support the body in a horizontal position. Extendable supports orarms 192 may be storable in the body to provide workpiece supportsurfaces 194 at axially adjustable and fixable positions.

The chop saw may include a base 196 and an arm 198 coupled to the base.Arm 198 may support a power-driven circular saw blade 200. Arm 198 maybe pivotably and slidably coupled to base 196. Pivotal motion of the armbrings saw blade 200 down to, and up from, a cutting position near base196, and sliding of the arm moves the saw blade on a cutting path 202across a workpiece, transverse to a longitudinal axis 204 defined bystand 182. Cutting path 202 may be adjusted from perpendicular tolongitudinal axis 204 (a square cut), to an oblique orientation tocreate a miter cut, by pivoting a central portion 206 of base 196 abouta vertical axis. Central portion 206 carries arm 198 and saw blade 200,and may be pivoted with respect to flanking portions 208 of base 196,which are clamped to stand 182. In other cases, saw blade 200 may bepivoted about a horizontal axis.

Positioner 184 may include a rail module or fence module 210, a powermodule 212 operatively coupled to and supported by the rail module. Thepower module may be described as a motor box, a drive unit, a powerhead, a control unit, and/or a drive/control unit. The positioner alsomay include bracket assemblies 214 that mount the rail module to stand182. Rail module 210 may be described as a rail assembly or a fenceassembly that includes a rail or beam 215, which may form a positionerframe that may be elongate. Beam 215 may be engaged by bracketassemblies 214, which also may be attached to central body 188 of stand182. Beam 215 may be mounted with a longitudinal axis 216 defined by thebeam disposed parallel to a measurement axis 217, which may intersectcutting path 202 to define an origin of the measurement axis. In someembodiments, saw 186 may be pivotable about a pivot axis to orient blade200 for miter cuts, and the measurement axis may intersect the pivotaxis and/or the cutting path at the pivot axis to define the origin. Inany event, beam 215 may (or may not) extend parallel to longitudinalaxis 204 of stand 182.

Bracket assemblies 214 may fix the relative positions of central body188 of the stand and beam 215 of positioner 184 over a range of relativelongitudinal positions, to permit a user to select how close the railmodule is disposed to the saw. For example, the rail module may bepositioned farther from the saw in order to cut longer products frompieces of stock.

Rail module 210 may include a drive linkage 102 comprising abelt-and-pulley assembly 218 operatively connected to a carriageassembly 220. Carriage assembly 220 may be coupled slidably to beam 215,to permit the carriage assembly to reciprocate (travel back and forth)parallel to longitudinal axis 216 and measurement axis 217, along a pathdetermined by beam 215. The carriage may carry a stop foot 222 as anembodiment of stop 52 (see FIG. 1), which can be positioned at a rangeof set point distances from cutting path 202 of saw blade 200.

A workpiece, such as a piece of lumber 224, may be supported andpositioned by saw system 180 using contact surfaces of stand 182,positioner 184, and/or saw 186. Piece 224 may, for example, be contactedand supported from underneath by contact of a lower/bottom surface ofthe piece with at least one bracket surface 226, a base surface or deck228 of saw 186, a top support surface 194 of at least one extendable arm192, or any combination thereof, to define the elevation of piece 224.The piece of stock also may, for example, be contacted on a front and/orback side surface using a lateral and/or front surface 230 of beam 215,a fence 232 of saw 186, and/or a fence structure formed by stand 182and/or one or more bracket assemblies 214. In combination, contact oflumber piece 224 on a bottom surface and a front and/or back side mayorient the piece parallel to measurement axis 217. Abutment of stop foot222 with an end surface of lumber piece 224 positions the piece alongmeasurement axis 217, to define axial placement of the piece of lumber.

Power module 212 may comprise a controller 236, a motor assembly 238,and a rotary encoder 240. Controller 236 may include any of theelements, features, and capabilities disclosed for controller 70 and maybe connected or connectable to any of peripherals 130 disclosed forcontroller 70 (see FIG. 2). Controller 236 may control operation ofmotor assembly 238 based on position signals from encoder 240 and basedon a “fixed” end point and/or dynamic end points calculated from a fixedend point. Motor assembly 238 may be operatively connected tobelt-and-pulley assembly 218, to form, collectively, at least a portionof drive assembly 68 (see FIG. 1). Operation of a motor of the motorassembly may drive coupled motion of the belt-and-pulley assembly,carriage 220, and stop foot 222. Controller 236 may use a feedbackmechanism to move stop foot 222 according to a target dimension or setpoint value received from a user.

In the configuration of positioner 184 shown in FIG. 3 for saw system180, and with respect to a user using the system, the positioner (andparticularly stop foot 222) is disposed to the left of the saw,generally along measurement axis 217. Stated differently, the tool is tothe right of the positioner. Power module 212 is connected to the railmodule near one of the rail module's opposing ends, namely, the opposingend closest to the saw, to dispose the power module and the saw close toone another, which permits the user to operate both the power module andthe saw conveniently, with minimal walking back and forth. However, theuser may prefer to set up saw system 180 with the positioner on theother side of the saw, namely, to the right of the saw with respect tothe user, such that the tool is to the left of the positioner.

III. EXEMPLARY EMBODIMENT OF A POSITIONING APPARATUS

FIG. 4 shows distinct configurations of positioner 184 that permit thepositioner to function on either side of a tool, such as saw 186 (seeFIG. 3); FIG. 5 shows a longitudinal portion of the positioner takenaround carriage 220 and stop foot 222; and FIGS. 6 and 7 show respectivetop and front views of the positioner. In FIG. 4, the positioner isillustrated in the absence of stand 182 and saw 186, and with bracketassemblies 214 disconnected from rail module 210; the bracket assembliesare not shown in FIGS. 5-7.

Power module 212 may be operatively coupled to rail module 210 and/orbelt-and-pulley assembly 218 near either opposing end 250, 252 of beam215 to drive movement of stop foot 222 to target positions alongmeasurement axis 217. Positioner 184 may be reconfigured from arightward tool arrangement (e.g., as in FIG. 3) to a leftward toolarrangement by (a) disconnecting power module 212 from its position nearright end 252 and reconnecting the power module near left end 250 (asindicated with the power module in phantom outline in FIG. 4), (b)changing the orientation of stop foot 222 (e.g., to the orientationshown in phantom outline in FIG. 4), (c) communicating a left/rightchange in tool position to the controller, or (d) any combinationthereof. In other words, the power module may function properly neareither end of rail module 210, whether a tool is to the right or theleft (or both), but a user may prefer to have the power modulepositioned closer to the tool.

Power module 212 may be connected to rail module 210 by one or morefasteners and/or a mated coupling of the power module to the railmodule. The mated coupling may transmit torque from a motor of the powermodule to a drive linkage of the rail module. The fasteners may restrictthe ability of the power module to move in relation to the rail module,such as turning and/or bouncing, among others, particularly while themotor is operating. In any event, power module 212 may be disconnectedfrom rail module 210 by releasing the fasteners and separating the powermodule from the rail module.

Power module 212 may be connected to the rail module by one or at leasta pair of quick-release fasteners 254 disposed adjacent opposing sidesof the power module, and also may connected by a mated coupling of thepower module's motor assembly 238 to belt-and-pulley assembly 218 of therail module.

More particularly, a rotatable member of the motor assembly (e.g., ashaft, gear, or pulley) may be engaged by an at least partially and/orat least generally complementary rotatable member (e.g., a gear, pulley,or shaft) of the rail module's drive linkage (i.e., belt-and-pulleyassembly 218), to provide a mated relationship of the motor assemblywith the drive linkage. For example, motor assembly 238 may include ashaft 256 structured to transmit torque to the drive linkage of the railmodule, without substantial slippage, generally in a meshedconfiguration. Accordingly, the shaft may include teeth and/or may bedescribed as a splined shaft, among others. The shaft may be received inmating relation with an opening 258 (also termed a socket) defined byrail module 210 near one or both opposing ends 250, 252 (see FIGS. 4 and6). The opposing ends may have similar structure and rail module mayhave at least substantial mirror image symmetry with respect to itscentral transverse plane. In any event, openings 258 may be defined nearboth opposing ends of the rail module, to permit mating with the powermodule near the left and right ends of the rail module. Each opening 258may extend to an exterior surface of the rail module, such that theopening is accessible for mating with shaft 256. Furthermore, eachopening 258 may communicate with any suitable surface of rail module 210and/or beam 215, such as a top surface 260 (as shown here), a bottomsurface 262, a front surface 264, a back surface 266, or an end surface268, among others (see FIG. 6).

Power module 212 may be disconnected from the rail module by releasingfasteners 254, and then withdrawing shaft 256 from opening 258 bylifting power module 212 vertically, indicated schematically by a motionarrow at 270 in FIG. 4. Power module 212 then may be movedlongitudinally along the rail module, indicated schematically by amotion arrow at 272, and then re-mated with the rail module nearopposing end 250 and re-secured with fasteners 254. In other cases,power module 212 may be disconnected from the rail module for transportand/or storage, and then later reconnected (or connected for the firsttime) to the rail module adjacent either end of the rail module,according to the user's left/right preference or need. In other matingconfigurations, separation and mating of the rail module and powermodule may be performed in a horizontal direction (e.g., mating at theback of the rail module) or in the vertical direction from below therail module.

FIGS. 8 and 9 show plan and sectional views of fastener 254 securingpower module 212 to beam 215 of rail module 210. Power module 212 may beequipped with opposing forks 280 each defining a notch 282 for receivinga fastener 254. Notch 282 may be defined between a pair of fingers 284of fork 280. A shaft 286 of fastener 254 may be received between thefingers. The frame may define a channel 288 (e.g., a generally T-shapedchannel) in a top surface of beam 215, with the channel sized to receivea head 290 of fastener 254 (see FIG. 9). An opposing end of shaft 286may be received in threaded engagement with a nut 292 disposed over awasher 294 and carrying a pivotably coupled cam lever 296. The lever mayhave an eccentrically mounted head 298. The head may act as a cam thatadjustably bears against washer 294 when lever 296 is pivoted betweenopen and closed positions, to release the fork from, and to secure thefork to beam 215 using fastener 254.

An elastomeric bumper 300 may project from any suitable surface of thepower module. For example, in the depicted embodiment, bumpers 300 areattached to the power module on opposing left and right sides. Bumpers300 may protect the power module from damage and/or may keep the powermodule spaced from an adjacent tool or frame structure.

Power module 212 may be equipped with features that facilitate handlingor protection of the power module (see FIG. 7). For example, the powermodule may have a handle 310 configured to be grasped by hand, tofacilitate lifting and/or carrying the power module with one hand. Insome embodiments, the power module may weigh less than about 25, 20, or10 pounds (i.e., less than about 11.25, 9, or 4.5 kilograms), which mayrender the power module readily portable, to permit positionerdisassembly and storage or transportation to different job sites, amongothers. Handle 310 may have any suitable position on the power module,such as disposed at or near the top, the back, a side, or a bottom ofthe power module. The power module also or alternatively may include acover 312 connected to a body 314 of the power module, with the coverhaving an open position and a closed position. Cover 312 may have ahinged connection to body 314, such that the cover pivots, indicated at316 (see FIG. 4) between open and closed positions. In some embodiments,the hinged connection may define a pivot axis 318 that extends throughthe handle, optionally with the central axis of the handle and the pivotaxis being coaxial (see FIG. 7). The closed position of the cover mayplace the cover in a substantially or completely overlappingrelationship with a display 320 and/or input controls 155, such as akeypad 322, of the power module. The cover thus may provide protectionto potentially fragile components during transport and storage of thepower module.

Stop foot 222 also may be reconfigured when the positioner is beingre-arranged for use with a tool near the other end of the rail module(see FIGS. 4 and 5). The stop foot may be re-oriented, generally by 180degrees, such that a datum surface 324 of the stop faces generallytoward the correct left/right side on which the tool is or will bedisposed.

Stop foot 222 may be included in a stop assembly 326 connected tocarriage 220 (see FIG. 5). The stop assembly also may comprise a wingmember 328 pivotably connected to carriage 220 at hinge joint 330, astop bar 332, or any combination thereof, among others. Wing member 328may support and be connected to stop bar 332, which, in turn, carriesstop foot 222. Stop bar 332 may be connected to wing member 328 ineither of the two opposing orientations shown in FIG. 4 at 334 (in solidoutline) and 336 (in phantom outline), according to the left/right sideon which the tool is disposed. In alternative embodiments, the stopassembly may include a pair of stop feet with respective datum surfaces324 facing toward left and right tool positions, such that the stopassembly does not need to be reconfigured if the tool position ischanged from left to right (or vice versa) and/or if the positioner isused with tools disposed concurrently on both left and right sides.

Stop foot 222 may be adjustably located with respect to carriage 220 byadjustment of the longitudinal, angular, and/or directional dispositionof stop bar 332 (see FIG. 5). The stop bar may be received in a passage338 defined by wing member 328. Stop bar 332 and passage 338 may havecomplementary cross-sectional shapes, for example, both may behexagonal. Stop bar 332 may be maintained in the passage at a selecteddisposition using fasteners 340 engaged with stop bar 332 at positionsthat opposingly flank the wing member. Exemplary fasteners 340 may bering clamps 342 that can be loosened, to permit the stop bar to slide,and then fixed in position. Accordingly, stop foot 222 may be placed ata selectable distance from the carriage, according to the user'spreference or need, and then fixed. In some embodiments, a spring 344may be disposed between fastener 340 and wing member 328. The spring mayabsorb shocks to the stop foot, to reduce damage to other components ofthe rail module. The tension of the spring may be adjusted by changingthe spacing between flanking fastener 340 and wing member 328 along stopbar 332.

FIG. 10 shows a sectional view of selected portions of rail module 210,particularly rail or beam 215, and a belt 360 of belt-and-pulleyassembly 218.

Rail module 210 may provide a beam 215 that is fixed with respect tomovable portions of the rail module, such as the carriage, the stopfoot, and at least most of the belt-and-pulley assembly. Beam 215 may anelongate frame member, which may or may not be continuous and/ormonolithic. The beam may be formed of any suitable material, such asmetal, polymer, or composite, among others. In exemplary embodiments,the beam may be formed of aluminum and/or may be an extrusion with asubstantially constant cross-sectional shape (i.e., except where thebeam has been modified after its formation (e.g., to create apertures inwalls thereof). The beam may have a top surface 364, a bottom surface366, a front surface 368, and a back surface 370 provided bycorresponding respective outer walls 372-378. The beam may be hollow.The beam also may include one or more inner walls (e.g., walls 380-384)disposed generally inward of the outer walls. Each inner wall may bevertical, horizontal, oblique, or a combination thereof. Each inner wallmay be at least generally parallel to an outer wall and may extend fromone outer wall to another outer wall (e.g., inner wall 380), from anouter wall to an inner wall, and/or from an inner wall to another innerwall (e.g., inner wall 382). The walls of the beam may define one ormore interior compartments 386, 388 that are at least substantiallyenclosed on four sides (e.g., the top, bottom, front, and back sides).The beam also or alternatively may form one or a plurality of exteriorchannels (e.g., channels 288, 390-398). The beam further may include oneor a plurality of exterior ridges, such as opposing ridges 404, 406above exterior channels 390, 392, respectively. The beam even furthermay include a dovetail projection 408, which may be described as awedge, and which, for example, may be formed near the bottom of the beam(and/or the top, front, or back of the beam) to create a wedge base. Thedovetail projection may be fan-shaped and may flare away from a centralvertical plane defined by the beam as the projection extends toward thebottom of the beam. The dovetail projection may facilitate connectingthe rail to other support structures, such as stands, tables,workbenches, and the like.

Belt 360 may include inner and outer belt segments 410, 412, which mayextend longitudinally in the beam and at least substantially parallel toone another. The inner belt segment may be disposed in inner compartment388 and the outer belt compartment may be disposed in one or more outercompartments formed by one or more exterior channels, such as exteriorchannel 398 or a sub-channel thereof. The outer belt segment may haveopposing inner and outer surfaces 414, 416. The outer belt segment maybe substantially exposed in the rail module. In other words, the outerbelt segment may form a portion of the exterior surface of rail module210, such as a portion of the back surface of the rail module.Accordingly, beam 215 may cover and/or outwardly overlap substantiallyless than all, or less than about one-half, of outer surface 416 ofouter belt segment 412 by area, such that the outer belt segment isexposed to form an exterior surface region of rail assembly 210.Alternatively, or in addition, a substantial portion of the width of theouter belt segment (measured vertically in the present example), such asat least about one half of the width, may be exposed to form an exteriorsurface region of rail module 210. The accessibility of outer beltsegment 412 from outside of the rail assembly may offer substantialadvantages over an enclosed belt found in prior art positioners, such aseasier installation, adjustment, and service of the belt. In any event,the belt segments may be arranged along an orthogonal axis 418 withrespect to one another. Orthogonal axis 418 may be perpendicular to thelongitudinal axis of the rail module and may be vertical or horizontal.

FIG. 11 shows a longitudinal sectional view of rail assembly 210, takenas indicated in FIG. 7. Belt-and-pulley assembly 218 may include belt360 and a pair of pulley assemblies 430 engaged with and operativelycoupled to the belt. Each pulley assembly 430 may include at least onepulley 432 pivotably coupled to beam 215, to provide rotation of eachpulley about a respective pivot axis 434. Each pivot axis 434 may bevertical, as shown here, or horizontal, among others.

Opposing ends 436, 438 of belt 360 may be connected to each other by abelt linkage or connector 440 to form a closed loop. The belt linkagemay (or may not) be considered part of carriage 220. When connected inthe closed loop, the belt extends around each pulley, and extendsbetween the pulleys to form inner and outer belt segments 410, 412,which also or alternatively may be described as longitudinal beltsegments. Longitudinal belt segment 412 may include belt ends 436, 438.

Rotation of pulleys 432 may be coupled by the belt. Conversely,translational motion of belt segments 436, 438 along the longitudinalaxis of the rail assembly and/or beam may be coupled to rotation of thepulleys.

Belt 360 and pulleys 432 may have at least generally complementarystructures to resist slippage of the belt with respect to each pulley.For example, the belt may have teeth 442 formed on the inner surface ofthe belt, and pulleys 432 may have complementary outer teeth 444 formedon an outer surface of each pulley. Each pulley 432 also may define achannel 446 centered on pivot axis 434 and configured to receive shaft256 of power module 212 (see leftward and rightward pulleys 432 in FIG.11; also see FIGS. 4, 16, and 26). Channel 446 may be described as afluted channel and/or may include inner teeth formed in the channel, toprovide meshed engagement with corresponding ridges formed on shaft 256.

FIGS. 11-13 show further aspects of belt linkage 440. The belt linkagemay comprise a pair of belt connectors 450, such as clamps 452, 454,that attach to the belt near respective belt ends 436, 438. Each clampmay include an outer clamp piece 456 and an inner clamp piece 458 thatsandwich a section of outer belt segment 412 between the clamp pieces(see FIGS. 11 and 12). One or more fasteners 460 may extend throughouter clamp piece 456 for threaded engagement with inner clamp piece458, to connect the outer and inner clamp pieces to one another and,optionally, to apply a compressive force to the flanked section of thebelt as the fasteners are tightened.

Belt connectors 450 may be interconnected with one another by at leastone spanning member 462, also termed a spacer, that extends from one ofthe connectors to the other connector. The axial position of thespanning member may be changed with respect to one or both of theconnectors to adjust the spacing between the connectors, and thus thetension of belt 360. For example, the spanning member may be a screw(which may be described as a threaded rod) that extends through a holedefined by one of clamps 452, 454 and into threaded engagement withanother hole defined by the other of the clamps. The screw may be turnedusing a driver engaged with a head 464 of the screw (see FIG. 11), tomove the clamps closer or farther from one another, which respectivelyincreases or decreases the tension of belt 360.

Belt tension adjustment near the ends of the belt, as disclosed above,may have substantial advantages. Prior art positioners generally adjustbelt tension by changing the spacing between pulleys. Accordingly, atleast one of the pulleys cannot be mounted at a fixed axial position inthe rail module. By contrast, the belt adjustment mechanism disclosedabove permits each pulley to be mounted using a simpler design at afixed axial position along the rail assembly.

Carriage 220 may incorporate a slider 480 of one or more discrete pieces(see FIGS. 5, 12, and 13). The slider may be structured to slide backand forth along beam 215. The slider may be disposed externally (orinternally) with respect to beam 215. For example, the slider may bedisposed outside (or inside), or at least mostly outside (or inside),the outer walls of the beam. The slider may be in slidable contact with,and/or supported by contact with, an exterior surface or an interiorsurface (or both) of the beam.

Slider 480 may be configured to slide along beam 215. The slider and thebeam may form complementary structures. The complementary structures maybe shaped to permit the slider to be received on (and/or in) the beam.The slider may be received by motion of the slider parallel to thelongitudinal axis of the beam, such as by introducing the slider ontoand/or into beam 215 from an end thereof, to mate the slider with thebeam. The complementary structures may restrict lateral uncoupling ofthe slider from the beam, that is, uncoupling by motion of the sliderorthogonal to the longitudinal axis of beam 215. Accordingly, beam 215may provide a box way for the slider.

Beam 215 may form a track 482 along which slider 480 slides (see FIG.12). The track may include one or more longitudinal channels and/orridges formed on or in the frame. Slider 480 thus may form one or moreridges and/or channels that are complementary to the track. For example,slider 480 may define a channel 484 that receives at least a portion oftrack 482 (see FIG. 13). Each of track 482 and channel 484 may be atleast generally T-shaped. Hook regions 486 of slider 480 may be receivedin opposing channels 390, 392 of beam 215 (see FIG. 13).

Slider 480 may include a body 488 and one or more low-friction elementsor slides 490 (also termed slide elements). In the present illustration,slides 490 are generally U-shaped and are received on opposing ridges404, 406 of track 482, such that body 488 is supported on the slides(see FIGS. 10 and 13). Slides 490 may be disposed between body 488 andbeam 215 at one or more spaced positions along a vertical axis and/oralong a horizontal transverse axis, to space the body from the beam, andto reduce friction that would occur if body 488 were in contact withbeam 215. Slides 490 may provide the only contact between slider 480 andbeam 215. The slides 490 may be formed of a low-friction material, suchas a low-friction polymer. In some embodiments, body 488 and beam 215both may be formed of metal. In some embodiments, beam 215 may be formedof or may include a low-friction material such that slide elements 490may be omitted from slider 480.

Slider 480 also may include one or more retainers or caps 496 torestrict longitudinal motion of slide elements 490 with respect to body488 (see FIGS. 5, 12, and 13). In exemplary embodiments, the retainersare structured as plates disposed at opposing ends of body 488 andsecured to the body with fasteners 500 (see FIG. 12).

Slider 480 further may be equipped with one or more slider adjustmentmechanisms 502 to adjust the fit of the slider with respect to track 482(see FIG. 13). Exemplary positions of mechanism 502 along the slider areillustrated in FIG. 15. Each mechanism 502 may utilize a set screw 504and, optionally, a pressure diffuser or gib, such as a plate 506 (seeFIG. 13). Set screw 504 may be threadably received in slider body 488and may bear against a slide element 490 and/or plate 506, which maydeform the slide element. The set screw may be turned by engagement ofits proximal end/head with a driver, to increase or decrease how tightlyslide element 490 bears against the beam. This adjustment may be used toreduce the amount of play, such as to reduce lateral play of the slideron beam 215.

Slider 480 may be attached to belt linkage 440 at slider body 488 (seeFIGS. 11 and 13-15). Body 488 and one or more of belt connectors 450 mayform complementary mating structures, indicated at 510 in FIG. 13. Forexample, body 488 may define a cavity (or protuberance) shaped toreceive a protuberance (or cavity) formed on (or in) outer clamp piece456. In any event, the complementary mating structures may be configuredto permit one or both connectors 450 to slide longitudinally withrespect to slider body 488, while the slider body remains mated to theconnectors. Furthermore, slider body 488 may be attached to connectors450 using one or more threaded fasteners 516 extending through slots 518defined by slider body 488, and into threaded engagement with theconnectors (e.g., with outer clamp piece 456 of each clamp)(see FIGS. 11and 15). The slots may allow fasteners 516 to be received in threadedengagement with connectors 450 over a range of separations of connectors450 produced by adjustment of the belt linkage.

FIGS. 16 and 17 show respective sectional and exploded views taken nearthe end of rail module 210. Pulley assembly 430 may include pulley 432and one or more bearings 530 that facilitate pivotal motion of pulley432 with respect to beam 215. Each bearing may be described as arolling-element bearing, such as a ball bearing or a roller bearing,among others.

Pulley 432 may comprise a midsection 532 flanked opposingly parallel topivot axis 434 by end sections 534, 536 (see FIG. 17). Midsection 532may be wider than one or both of the end sections, which may have thesame or distinct diameters. Midsection 532 may include outer teeth 444.Inner teeth 537 or channels for engagement with the motor assembly maybe disposed in any suitable sections of channel 446 of pulley 432 (seeFIG. 16).

Bearings 530 may be received on the pulley, and particularly onrespective end sections 534, 536, such that access to channel 446 alongthe pulley pivot axis, from at least one of the opposing ends of thechannel, is not obstructed. Accordingly, each bearing may define acentral opening 538 that is sized in correspondence with its respectiveend section 534, 536. Each bearing may include an inner member 540 andan outer member 542 (e.g., an inner ring and an outer ring, amongothers) connected by rolling elements 544, such as balls or cylinders.Each inner member 540 may be in contact with pulley 432 and each outermember 542 with beam 215. Accordingly, rolling elements 544 enablepulley 432 (and inner member 540) to spin freely about pivot axis 434relative to a stationary beam 215 (and outer member 542).

Pulley assembly 430 may be received in a cavity 546 formed by beam 215,and particularly by outer and/or inner walls thereof. Accordingly, thepulley assembly may be mounted in the beam, with the assembly having afixed pivot axis defined by cavity 546. Cavity 546 may be sized and/orshaped in correspondence with the respective size and shape of thepulley assembly. The cavity may be at least substantially coaxial withthe pulley assembly, such that a central axis 548 defined by the cavityis coincident with pivot axis 434 of pulley 432.

The cavity may be formed in part by apertures 550-558 formed in outerand/or inner walls of the beam (compare FIG. 10 with FIGS. 16 and 17).Each aperture may be circular or noncircular, and the apertures may havethe same or different widths/diameters relative to one another. Inexemplary embodiments, apertures 550-558 are formed by a drill, and forma stepped cavity. A smaller aperture 550 (see FIG. 16), whichcorresponds in size to end section 534 of the pulley, may be formed intop outer wall 372 (see FIG. 10). Also, larger apertures 552-558 (seeFIGS. 16 and 17) may be formed at least partially in inner walls 380,382, 384 and bottom outer wall 374 (see FIG. 10).

Beam 215 may restrict motion of the pulley assembly received in thebeam. In particular, translational motion of the pulley assemblyperpendicular to pivot axis 434 and in one (or both) of the opposingdirections parallel to pivot axis 434 may be restricted by contact withthe walls of the beam at the perimeter of the cavity. Translationalmotion of the pulley assembly in the other opposing direction parallelto pivot axis 434 may be restricted by a retainer 560, such as a C-clip562 received in cavity 546 and engaged with a wall of the beam (e.g.,bottom outer wall 374, in a groove formed therein).

Beam 215 may include a side cover 580 and an end cap 582 disposed ateach opposing end region of the beam (see FIGS. 14, 16, and 17). Eachcap/cover may be a plate. Also, side cover 580 and end cap 582 may bediscrete pieces or may be connected integrally (as shown here).

The side covers, collectively, may extend along only a fraction of thelength of beam 215. Side covers 580 that are short may be suitable to,for example, avoid interfering with travel of carriage 220. Accordingly,each side cover may extend to a position adjacent belt 360 near pulleyassembly 430, such as near one of the opposing ends of outer beltsegment 412. This location of the side cover may improve safety byrestricting access to the belt where it extends away from outer beltsegment 412 toward internal compartment 388 of beam 215. (Compareopposing ends of rail module 210 in FIG. 14, where the side cover isinstalled on only one end region.) In some embodiments, the side coversmay act as travel barriers, to define a range of travel for the stop(see below) and/or to act as a back-up barrier to reduce damage to thebelt if one or more of the usual travel barriers is missing (see below).Each side cover 580 may be received with its edges disposed in anexterior channel of the beam.

End cap 582 may at least substantially cover an end of beam 215, andthus the end caps collectively, in combination with the beam, mayenclose interior compartments 386, 388 on six sides (also see FIG. 10).The end cap (and, optionally, the side cover if connected integrally)may be secured with a fastener 584 received in a passage formed by innerwall 382 of beam 215 (see FIGS. 10 and 17).

FIGS. 11 and 14-17 show travel barriers 588, 590 that restrict travel ofcarriage 220 in respective opposing longitudinal travel directions. Eachbarrier may be configured to limit travel of the carriage by physicalcontact of the barrier with the carriage. In other words, each barriermay be disposed in a travel path of a portion of the carriage, to blockcarriage motion parallel to the measurement axis. Each barrier may berigid or flexible. A rigid travel barrier, such as a barrier formed ofmetal, may be desirable in some cases to create a “hard stop” that moreaccurately defines the site at which carriage travel is blocked. Aflexible travel barrier, such as a barrier formed of an elastomer, maybe desirable in some cases to create a “soft stop” that is quieter andless likely to damage the carriage.

Each travel barrier may have any suitable structure and any suitableposition with respect to the travel path of the carriage. For example,in the present illustration, each travel barrier is a fastener, such asa screw, disposed in threaded engagement with beam 215 via outer wall378. The screw may have a head that occupies the travel path and thatcontacts carriage 220 to block carriage motion. For example, the head ofthe screw may be disposed in one of the exterior channels formed in beam215, such as channel 392 or 394, among others (see FIG. 10). In someembodiments, the fastener may attach another contact structure, such asan elastomeric bumper to the beam. In any event, the travel barrier mayblock carriage travel by, for example, contact with slider body 488and/or retainer 496 of the carriage, among others.

The travel barriers may define a range of linear travel of carriage 220(and thus stop foot 222 and/or the stop). The range of travel is thedistance a point on the carriage/stop travels when the carriage movesfrom blocked travel at one end of the travel path to blocked travel atthe other end of the travel path. The range of travel generallycorresponds to the distance between the travel barriers measuredparallel to the path of travel, minus the length of the carriage,measured in the same direction, between respective contact sites oncarriage 220 for travel barriers 588, 590. The range of travel may bepredefined precisely during manufacture of the positioner. For example,the travel barriers may be attached to the beam with a precise spacing,such as by using a jig, to provide a standard range of travel.Alternatively, or in addition, the spacing of the travel barriers may bemeasured during manufacture, after their placement, using a measuringdevice. The range of travel may be selected to correspond to an integermultiple of a linear measurement unit, such 8, 10, 12, 15, or 20 feet,or 3, 4, 5, or 6 meters, among others.

Mitered ends of workpieces may be generated in various constructionactivities, such as by finish carpenters as casings for windows anddoors. Baseboards also may be mitered in low end construction. The sawsystems disclosed herein may provide compensation for miter cuts. Forexample, some finish carpenters like to have shear cuts when mitering,which means the measured edge (the inside dimension) may be spaced fromthe longitudinal fence. Further aspects of miter compensation aredisclosed elsewhere herein, such as in Section VI (Examples 2-4), amongothers.

FIGS. 18 and 19 show fragmentary, plan views of positioner 184 incontact with and defining the positions along measurement axis 217 ofrespective mitered and square-cut workpieces 620, 622. Positioner 184may be structured to dispose respective mitered and square ends 624, 626of workpieces 620, 622 at distinct distances from the cutting path of asaw and from an end 628 of beam 215, for the same position of stop foot222. For example, an outer corner 630 (and, optionally, an inner corner632) of mitered end 624 may be offset in a direction parallel tomeasurement axis 217 by an offset distance 634 from square end 626.

Workpiece ends 624, 626 also or alternatively may be described asoblique and orthogonal workpiece surfaces, respectively. Workpiecesurfaces described as orthogonal or oblique define planes that areorthogonal and oblique with respect to a characteristic workpiece axis(e.g., a longitudinal axis, or either of the characteristic transverseaxes). Furthermore, an oblique workpiece surface may define an obliqueplane that is related to an orthogonal plane by rotation about acharacteristic transverse axis of a workpiece.

Stop foot 222 may include oblique (miter) stop surface 636 andorthogonal (square) stop surface 638 (see FIG. 18) for respectiveengagement of mitered end 624 and square end 626 of workpieces 620, 622(see FIG. 19). Each stop surface 636, 638 may be substantially planar ornonplanar. Miter stop surface 636 may define an oblique plane orientedat any suitable angle with respect to orthogonal stop surface 638, suchas 45 degrees (to accommodate the most common miter angle), or may becurved to accommodate a range of miter angles (see below), among others.Square stop surface 638 at least generally faces end 628 of beam 215 andtool 54. Miter stop surface 636 may be disposed farther from beam end628 than square stop surface 638. Also, miter stop surface 636 may bedisposed adjacent square stop surface 638, such as toward beam 215 fromsquare stop surface 636. Alternatively, miter stop surface 636 may beformed in square stop surface 638, which may separate square stopsurface 638 into spaced stop regions, which may opposingly flank miterstop surface 636 (see below).

Stop foot 222 alone, or in combination with beam 215, may formrespective receiver regions 640, 642. Receiver region 640 may be shapedto receive an acute corner (a mitered tip) of the mitered workpiece, andreceiver region 642 may be shaped to receive a right angle corner of thesquare workpiece. Each receiver region may engage both convergingsurfaces of the corner, which may define the position of each workpiecein a horizontal plane. In any event, when disposed in receiver region640, the mitered tip may be disposed between stop foot 222 and beam 215,such that converging surfaces of the tip are contacted by the stop footand the frame, respectively. In this position, the tip may be trapped inreceiver region 640 to restrict lateral motion of the tip (horizontally,orthogonal to measurement axis 217). Stop foot 222 may be disposed incontact with beam 215 or may be spaced from the beam by any suitabledistance.

FIG. 20 shows a fragmentary view of another embodiment of positioner 184with another exemplary stop foot 660 for engagement of square andmitered ends of workpieces. Stop foot 660 may be spaced from beam 215,to form a receiver region 662 collectively with beam 215, for at least aportion of a tip 664 of a mitered workpiece 666. Receiver region 662 maybe formed in part by an end stop surface 668 of stop foot 660, which maybe curved. Curvature of stop surface 668 may permit an oblique surface670 of workpiece 666 to contact stop surface 668 tangentially over arange of angles of the oblique surface. Accordingly, receiver region 662may receive and abut mitered tips having a range of miter angles. Stopfoot 660 also may form another receiver region using an orthogonal stopsurface and beam 215 to engage and position converging surfaces of aright angle corner of a workpiece. A potential disadvantage of stop feet222 and 660 for use with a mitered workpiece is that the miteredworkpiece may function as a wedge to urge each of these stop feet awayfrom the frame, which may cause inaccuracies in workpiece positioning.

FIGS. 21 and 22 show fragmentary views of yet another embodiment ofpositioner 184 with another exemplary stop assembly 690 for engagementof square and mitered corners of workpieces. Stop assembly 690 may beequipped with a stop foot 692. The stop foot may receive a portion of aworkpiece 693, namely, a mitered tip 694 thereof, and engage convergingsurfaces 696, 698 of the tip. Stop foot 692 may be superior to stop feet222 and 660 for receiving a mitered workpiece because the miteredworkpiece is not wedged between the frame and the stop foot.

Stop assembly 690 may be connected to carriage 220 and may comprise awing member 700 connected to carriage 220 via a pivotable joint 702. Thestop assembly also may comprise a stop bar 704 connected to wing member700 and also connected to stop foot 692 at an end of the bar.

Stop foot 692 may provide an orthogonal stop surface 706 facing at leastgenerally towards an end of beam 215 and positioned for abutment with anorthogonal surface (e.g., a square end) of a workpiece. Stop surface 706may be formed by a body 710, one or more fingers 712, or by body 710 andat least one finger 712 of stop foot 692, among others. Accordingly, atip of each finger 712 may engage a facing orthogonal surface of asquare-cut workpiece or may be set back and thus spaced from theworkpiece's orthogonal surface.

Stop foot 692 may include a recess 716 (see FIG. 21) formed in and/oradjacent orthogonal stop surface 706, to provide a receiver region forsurfaces 696, 698 of mitered workpiece tip 694. For example, finger 712may engage parallel surface 696 of workpiece 693 and body 710 may engageoblique surface 698 of the workpiece. Parallel surface 696 may be a sidesurface of the workpiece disposed parallel to measurement axis 217.

Finger 712 may space tip 694 of workpiece 708 from beam 215.Accordingly, the workpiece may be skewed slightly, indicated at 718, inthe horizontal plane with respect to measurement axis 217, if beam 215is utilized as a fence to align the workpiece with measurement axis 217.As a result, the set angle at which a saw is set to cut through theslightly skewed workpiece (e.g., to form a square or miter cut) may bechanged by the skew angle at which the workpiece is skewed. However, theskew angle generally becomes negligible with longer workpiece products.As an example, intended for illustration only, the finger width may beless than about one percent of the length of a desired product, such asa finger that is 0.25 inch wide and a cut product that is 2 feet long.These dimensions yield a skew angle of 0.6 degrees, which is withinacceptable tolerances for most applications. Alternatively, the skewedarrangement of the workpiece may be avoided by various approaches. Forexample, if the tool has a fence, the tool's fence may be moved forwardof beam 215 by the width of finger 712. With this approach, finger 712and the tool's fence may be used to position the workpiece parallel tothe measurement axis in a horizontal plane. As another example, a widthof beam 215 measured horizontally may be increased locally by an amountequal to the width of finger 712, near the end of beam 215 adjacent thetool. A local increase of the beam's width may, for example, be achievedby attachment of a plate over the front surface of beam 215 near itsend. The plate may be positioned beyond the range of travel of the stopfoot, such that motion of the stop foot is not impeded by the plate.

Body 710 and finger 712 (or two or more fingers 712) may be present inthe same monolithic stop structure or may be present as discrete parts.In exemplary embodiments, stop foot 692 may be formed as one piece(e.g., from an extrusion) having a substantially constantcross-sectional shape, such as along a vertical axis when the stop footis positioned as in FIG. 21. Body 710 may be hollow or solid.

Each of stop feet 222, 660, and 692 disposes an outer corner of amitered end and a square corner at an offset with respect to oneanother. Accordingly, the positioner's controller may position any ofstop feet 222, 660, and 692 at distinct positions along measurement axis217 for the same target dimension, based on whether the controller isinformed that a workpiece has a mitered end or a square end forengagement with the stop foot. Further aspects of controller calibrationand/or compensation for square and mitered ends are described below withrespect to controller routines in Sections V and VI.

Stop bar 704 may be connected to wing member 700 with a clamp 730 (seeFIGS. 21 and 23). The clamp may comprise a clamp body 732 defining anopening 734 to receive stop bar 704. Clamp body 732 may be at leastgenerally U-shaped and/or may be integral to wing member 700. The clampalso may comprise a fastener 736 that extends between opposing legs ofthe clamp member and that is in threaded engagement with only one of thelegs. Fastener 736 may be connected to a handle 742, such as a lever,that can be turned to adjust the spacing of the clamp's legs, to providean adjustable configuration in which the stop bar is slidablelongitudinally with respect to the clamp and a fixed configuration inwhich the stop bar is fixed.

Wing member 700 further may incorporate an angle adjustment mechanism746. Mechanism 746 may be adjusted to determine an angle with which wingmember 700 extends from slider 480, and thus a height and angulation ofstop foot 692. In exemplary embodiments, mechanism 746 may, for example,be an adjustable set screw 748 that extends from an upper region of thewing member and into contact with slider 480. Set screw 748, by changingthe angle of the wing member, may be utilized to adjust a spacing ofstop foot 692 from beam 215.

Generally, the stop foot may be positioned at any suitable distance frombeam 215. In some embodiments, the stop foot (and/or stop) may be incontact with beam 215. For example, friction may be minimized by formingan interface, between the stop foot and the beam, that has a lowcoefficient of friction. In some embodiments, the stop foot (and/orstop) may be spaced from the beam, such as by a short distance (e.g.,less than about 2, 1 or 0.5 millimeters, among others) or a longerdistance (e.g., greater than about 1, 2, or 5 millimeters, amongothers), to avoid friction that might hinder stop motion. Placing thestop foot in contact with the beam or spaced by only a short distancemay be suitable to avoid a large gap between the stop with the beam,such as to permit an acute tip of a miter-cut workpiece to contact thestop foot near the beam without getting wedged in a large gap betweenthe stop foot and the beam.

FIGS. 24 and 25 show fragmentary views of another exemplary stopassembly 750, which may be incorporated into any of the positionersdisclosed herein. Stop assembly 750 may include any of the components orfeatures of other stop assemblies disclosed herein, such as wing member700, stop bar 704, and clamp 730 of stop assembly 690 (see FIGS. 21-23).

Stop assembly 750 may include a stop provided by a stop foot 752connected to an end of stop bar 704. Stop foot 752 may be shaped as arectangular block or plate, which may be structured as a parallelepiped.The stop foot may provide a transverse fence forming a flat abutmentsurface 754 (a datum surface) that a workpiece 756 may contact for axialpositioning of the workpiece. Surface 754 may be oriented orthogonal tothe longitudinal axis of beam 215. Workpieces having square and obliqueends may be abutted with surface 754. For example, in FIG. 25, a tip 758formed by a miter-cut end (a pointed end) of workpiece is abutted withstop foot 752 at surface 754.

FIG. 26 shows an exploded view of power module 212. The power module mayinclude a housing 760 that substantially encloses controller 236,encoder 240, a motor 762, or any combination thereof, among others.Housing 760 may incorporate a pair of housing elements 764, 766 that aresecured to one another with fasteners, to form a chamber 768 in whichcontroller 236 and motor 762 are housed.

The housing may define a plurality of openings 770-776, which may permitelectrical input and output and mechanical output, among others.

Opening 770 may receive a socket member 778. The socket member mayprovide a port for input of electrical power, such as line power orbattery power, and may be electrically connected to controller 236.

Opening 772 may receive shaft 256 of motor assembly 238. The shaft maybe rotationally coupled to motor 762 via a shaft linkage 780, which may(or may not) be disposed in housing 760. The shaft linkage may beseparated from other components of the power module by a partition, suchas a plate 782. The shaft linkage may be any linkage that transmitstorque from motor 762 to shaft 256, such as a belt-and-pulley assembly784 that includes a smaller pulley 786 rotationally coupled to a largerpulley 788 by a belt 790. Belt-and-pulley assembly 784 may provide agear reduction that causes shaft 256 to turn more slowly than motor 762,such as by a ratio of about 5:1. The use of a gear reduction may improvethe accuracy with which shaft 256 can be controlled. In particular, thegear reduction may cause the position signals received by the controllerfrom encoder 240, to correspond to smaller angles of rotation of shaft256, according to the gear reduction, than if the gear reduction werenot implemented.

Opening 774 may receive display 320, which is connected electrically tocontroller 236. Display 320 may be mounted on a circuit board 792. Thecircuit board may at least substantially provide the circuitry ofcontroller 236. Accordingly, the controller may be provided by asingle-board, which may have a mixed analog/digital hardware design. Theuse of a single-board controller may offer inexpensiveness, simplicity,and reliability. The circuit board may be potted in epoxy. The circuitboard and/or display may be designed for easy replacement by a user. Forexample, each may be replaced by snap-in installation without the needfor separate fasteners or tools.

Opening 776 may receive a connector, such as a ribbon connector 794,that electrically connects keypad 322 to controller 236. Keypad 322 maybe connected to housing 760 and disposed outside of housing 760, such ason an outer surface of the housing 760. The keypad may have a clearwindow or outer membrane, which may, for example, prevent dirtpenetration,

FIG. 27 shows a plan view of display 320 and keypad 322. The keypad mayinclude any combination of keys.

The keys may include a power button 812 and numerical input keys 814.The power button may be used to power on and/or off the controller andmay be described as a soft-start key. Keys 814 may include number keys816 (0 to 9), a decimal point key 818, a fraction key 820, unit keys822, 824, and a clear key 826. Keys 814 may be utilized by a user toinput any numerical data, particularly dimensions, such as setpoints/target dimensions and/or one or more calibration measurements(see below), among others. Decimal point key 818 may be used to providea decimal form of a dimension, such as “1”+“Ft”+“7.8125” (feet areindicated by pressing foot key 822 and inches are assumed by thecontroller without pressing inch key 824). Fraction key 820, may be usedinstead of decimal point key 818, to input the fractional form of thesame dimension, by pressing “1”+“Ft”+“7” “In”+“13” “/”+“16,” with inchkey 824 being used to signal the start of the fraction. In other words,decimal and fractional formats of a numerical input, such as a targetdimension, may be inputted according to the user's preference, with thecontroller programmed to recognize and display either format, andwithout the need to toggle a separate display format setting. Thus, thecontroller may be programmed to receive and display target dimensionsadaptively: the target dimensions may be entered in either decimal formor fractional format by a user and the controller may display the targetdimensions according to the format in which the target dimensions wereentered.

Furthermore, a user may input the same dimension, such as 24 inches bypressing “2”+“Ft” or “2”+“4”+“In,” or just “2”+“4,” with inches being adefault input unless specified otherwise. The controller may beprogrammed to enable keys 814 also or alternatively to be utilized toinput non-numerical data to the controller, system configuration (toolto left/right of positioner), user preferences (e.g., metric or Englishunits), or the like. Any of the other keys of the display also oralternatively may be configured to input non-numerical data to thecontroller.

The keys of the keypad may include a start key 828, which may have agreen background, and a stop key 830, which may have a red background.Start key 828 may function as an “enter” key that accepts an inputtedvalue, such as a set point value, and/or that signals that the user isready for the positioner to move the stop to a set point. Accordingly,pressing the start key may initiate movement of the stop toward a setpoint (a target position). Stop key 830 may be pressed to terminate apositioner operation, such as a drive sequence toward a set point.Accordingly, pressing the stop key may cause operation of the motor tocease temporarily and/or a drive sequence to be aborted.

The keys of the keypad also may include a calibration key 834. Key 834may be identified by a graphic representation, such as an illustrationinvolving a stop and/or a saw blade, among others. Pressing key 834 maysignal that a user is inputting calibration data, wants to initiate acalibration routine, or the like.

The keys of the keypad further may include a list key 836. The list keymay be employed to store a list of two or more data entries, such as twoor more set points for later use. Alternatively, or in addition, thelist key may be utilized to recall set points stored as a list.

The keys of the keypad still further may include a nudge key 838. Thenudge key may be pressed to increment the current position by apredefined or inputted value (e.g., 0.05, 0.1, or 0.2 inch or 0.5 or 1mm, among others), to add or subtract the value to or from a set pointand/or current stop position. The nudge key may function as two distinctkeys that may be operated by pressing the nudge key at distinctpositions 840, 842 to signal a positive or negative increment to thecurrent position.

The keys of the keypad also may include a plurality of miters keys844-850 to input miter-related data and/or to identify a set point asbeing for a particular miter-related configuration of stop abutment andsaw angle. Any of miter keys 844-850 may be identified by, be associatedwith, and/or bear a graphic representation (also termed a graphic) thatillustrates the function of the miter key. Width key 844 may beidentified by and may present a graphic representation 852 of a widthdimension, “w,” of a workpiece (and/or of a product to be generated),such as a piece of molding to be miter cut (e.g., at 45 degrees). Miterkey 846 may be identified by and may present a graphic representation854 of a “square-miter” inside dimension, “x,” of a mitered product,which corresponds, for example, to a short point of a left stile casing.Miter key 848 may be identified by and may present a graphicrepresentation 856 of a “miter-miter” inside dimension, “y,” of amitered product, which corresponds, for example, to a short point of aheader casing. Miter key 850 may be identified by and may present agraphic representation 858 of a “miter-square” inside dimension, “z,” ofa mitered product, which corresponds, for example, to a short point of aright stile casing.

The miter keys may have any other suitable properties. Each of the miterkeys may (or may not) be dedicated miter keys that are usedpredominantly or at least substantially exclusively for mitercompensation. The miter keys also may include an angle key for input ofan angle value for miter compensation (i.e., an angle value related to amiter cut at one or both ends of the product). The angle key also mayinclude a graphic representation illustrating the function of the key,namely, conveying the concept of an angle to the user.

IV. EXEMPLARY BRACKET ASSEMBLIES

This section describes exemplary bracket assemblies for attaching apositioning apparatus, such as positioner 184, to a support frame.

FIGS. 28 and 29 show respective side elevation and exploded views ofbracket assembly 214, which may be utilized in the saw system of FIG. 3to attach rail module 210 to chop saw stand 182 via central body or beam188 of the stand. Bracket assembly 214 may include an upper clamp 860and a lower clamp 862, which adjustably engage upper beam 215 and lowerbeam 188, respectively. Upper clamp 860 may include clamp members 864,866, which may opposingly engage dovetail projection 408 of beam 215.Clamp member 866 may be adjustably positioned relative to clamp member864 by turning a handle 868. Lower clamp 862 may include clamp members870, 872, which may opposingly engage beam 188 of stand 182. Clampmember 872 may be urged toward clamp member 870 by turning a fastener874.

Bracket assembly 214 may have an adjustable height provided by upper andlower bracket pieces 876, 878 carrying the upper and lower clamps,respectively. Bracket pieces may be attached to one another in a fixedconfiguration using fastener assemblies 880 received in aligned aperturepairs 882, 884 defined by the upper and lower bracket pieces.Alternatively, the bracket pieces may be attached to one another in anadjustable configuration by placing fasteners through vertical andhorizontal slots 886, 888 arranged in an overlapping configuration,indicated at 890 in FIG. 28, with the slots defined respectively by thebracket pieces. In the adjustable configuration, the relative positionsof the upper and lower clamps can be adjusted vertically and/orhorizontally and then fixed.

FIGS. 30 and 31 show respective side elevation and exploded views ofanother exemplary bracket 910 attached to rail module 210 of positioner184 and configured to secure beam 215 to a base, such as workbench.Bracket 910 may include a plate 912 with a hook 914 that is sized andshaped to be hooked onto dovetail projection 408, with the body of theplate disposed parallel to the bottom of beam 215. An opposing side ofdovetail projection 408 may be engaged by a washer 916 secured by a nut918 threaded to a post 920 projecting from the body of the plate,generally opposing hook 914. Post 920 may be fixed to plate 912. Plate912 may define apertures 922 for receiving fasteners that attach theplate to a base, such as a workbench.

V. EXEMPLARY CONTROL AND OPERATION OF A POSITIONING APPARATUS

This section describes exemplary controller algorithms, userinteractions with the controller, and operating procedures that may beutilized during operation of any of the positioning apparatus and/orgauge systems disclosed herein. The algorithms and procedures presentedin this section are described with reference to the elements ofpositioner 184 (e.g., see FIG. 3).

A setup routine may be performed at any time to prepare the positionerfor accurately driving the stop to set points. The setup routinegenerally is performed when the positioner is used for the first time.However, selected portions or all of the setup routine may be repeatedat any suitable later times, such as each time the controller is startedup, when the positioner has been reconfigured (such as by moving powermodule 212 from one end region to the other end region of the railmodule), or when the user chooses to recalibrate the positioner (e.g.,to check or improve the accuracy of stop positioning at set points,among others).

The setup routine may involve any suitable combination of (1) internalcalibration to determine a scale factor using an internal standard builtinto the positioner, (2) external calibration to determine an actualdistance of the stop from a tool by using one or more externalstandards, and (3) establishment of a polarity of measurement axis 217with respect to rail module 210.

Internal calibration, which may be described as determination of a scalefactor, may be performed in response to a command from a user and/orautomatically at one or more times determined by the controller.Automatic internal calibration may, for example, be suitable when thepositioner is used for the first time by a user.

Internal calibration may be based on an internal standard incorporatedinto the design of the positioner. In exemplary embodiments, theinternal standard may correspond to a predefined range of linear travelfor the carriage (and/or the stop). The linear range of travel may bepredefined by a pair of travel barriers 588, 590 set at a predefinedspacing from one another (see FIGS. 11 and 14-17). The predefined rangeof linear travel may be communicated to the controller at any suitabletime, such as inputted during manufacture or inputted by the user afterthe first start up (e.g., based on a stated range of linear travelassociated with the rail module being used).

The controller may follow an internal calibration routine in whichrotary position sensor 240 of positioner 184 communicates positionsignals to controller 236 as motor 762 drives carriage 220 through thepredefined range of travel. The position signals provide a range ofrotary travel for the motor, when the motor drives carriage 220 from oneend to the other end of the range of linear travel. The controller maycorrelate the position signals and the range of rotary travel, when thecarriage travels from one travel barrier to the other travel barrier,with the predefined range of linear travel, to determine a scale factor.The scale factor, which may be described as a linear-rotary conversionfactor, corresponds to a relationship between rotary motion of motor 762and linear motion of carriage 220/stop foot 222, such as a ratiocorresponding to a linear distance traveled by the carriage (and stopfoot) per rotary position signal received from the encoder, or thereciprocal of this ratio.

Each position signal may correspond to rotation of the motor through asmall angle (e.g., about one degree or less). The position signal may begenerated by sensing rotation of an encoder wheel coupled to the motor.The encoder wheel may carry a plurality of encoder marks arranged arounda pivot axis of the wheel. Rotary position signals (pulses) may begenerated as the encoder marks are sensed sequentially while the wheelrotates. In exemplary embodiments, the encoder wheel may carry about 500encoder marks. The controller/encoder may count position signals overthe range of the travel, and the controller may calculate a ratio of therange of linear travel to the number of position signals counted, orvice versa, among others. Also, or alternatively, the controller maycorrelate the position signals with the beginning and the end of therange of linear travel. Accordingly, a position signal from at leastsubstantially the start point of the range of rotary travel may beconsidered as corresponding to a zero point in the range of lineartravel, and a position signal from at least substantially the end of therange of rotary travel may be considered as corresponding to the lineardimension (of the range of linear travel) from the start point (e.g., +8(or −8) feet from the zero point). In any event, the scale factor may beused to convert rotary position signals into linear dimensions, and viceversa.

An exemplary scale factor calculation and use of the scale factor tocontrol motor operation are presented here for the purposes ofillustration only. The controller may have data corresponding to a rangeof travel of 8 feet (96 inches) stored in memory. The rotary encodermay, for example, send 48,000 position signals to the controller whenthe carriage/stop moves from one end to the other end of its range oflinear travel and the motor rotates through its full range of rotarytravel. The range of linear travel, 96 inches, divided by the range ofrotary travel (i.e., the number of position signals, 48,000) provides ascale factor of 0.002 inch of linear travel per encoder mark (andposition signal). Thus, in this illustration, the controller drives themotor through a measured rotation of five hundred encoder marks per inchof linear stop travel. Accordingly, if the controller receives a commandto move the stop by twenty-four inches, the controller sends drivesignals to the motor, to cause the encoder wheel to revolve until 12,000position signals (24 inches times 500 encoder marks per inch) have beendetected.

The controller may store an initial scale factor, which may be aprovisional scale factor. The provisional scale factor may be used bythe controller until internal calibration is completed, which maydetermine a revised scale factor that replaces the initial scale factor(or current scale factor). In some cases, the controller may display anerror message and/or reject a revised scale factor, if the revised scalefactor differs from the initial scale factor by at least a thresholdamount (e.g., an absolute or proportional amount). The provisional scalefactor may be inputted to the controller and/or calculated by thecontroller during manufacture of the positioner or may be communicatedto the controller at first start-up of the positioner by a user, amongothers. The provisional scale factor may be an approximate scale factorsuch as an average or representative value for the configuration of thedrive assembly, rotary encoder, and rail utilized by the positioner. Insome cases, the initial scale factor stored by the positioner may beaccurate enough to be used without revision, and thus internalcalibration after purchase may be unnecessary.

In some cases, the controller can determine automatically, based oninternal calibration, which length of rail module is being utilized inthe positioner, from among a set of two or more candidate lengths. Thecontroller (e.g., during manufacture or setup) may receive and storedata corresponding to a set of candidate ranges of linear travel (e.g.,8, 10 and 12 feet) for rail modules manufactured with distinct lengths.During internal calibration, the controller may identify one of thecandidate ranges of linear travel as corresponding most closely to themeasured amount of rotary change achieved by the motor. This measuredamount of rotary change may correspond to the rotary range of travel ofthe positioner's motor when the carriage is driven from one end to theother end of the range of linear travel. As an example for illustration,the candidate ranges of linear travel may correspond to rotation ofapproximately 48, 60, and 72 thousand encoder marks past the encoder'ssensor. The controller thus may compare (a) the actual number of encodermarks sensed with (b) an approximate expected number of encoder marksfor each candidate range of travel, to select the closest candidaterange of travel. A revised scale factor then may be calculated based onsetting the range of linear travel of the positioner to the selectedcandidate range. The revised scale factor and identified range of lineartravel then may be used in subsequent positioning operations by thecontroller.

In some embodiments, the travel barriers may be used after thecontroller is powered on to ascertain stop position and/or to determinerange of travel based on a preset scale factor. The controller may drivethe stop through its range of travel, from one travel barrier to theother, and then calculate and, optionally, display, a value for therange of travel based on a stored scale factor and position signals fromthe sensor. This procedure may allow a user to determine whether or notthe range of travel reported to the user is close to expected. Forexample, if the nominal range of travel is 96 inches, and the controllerreports a range of travel that is not close to 96 inches, the user maybe alerted that the system is not set up and/or functioning properly.Alternatively, or in addition, the controller may drive the stop throughits entire range of travel to correlate each end of the range of traveland the distance between the ends with particular position signals fromthe sensor.

In some embodiments, the controller may drive the stop to an end of itsrange of travel when the current location of the stop within the travelpath is not certain. In particular, the controller may drive the stopuntil movement of the stop is halted by the contact of the carriage withthe travel barrier, to define the current location of the stop, namely,at one or the other end of the range of travel. The position of the stopmay be uncertain any time the controller loses contact with the positionsensor and/or position data from the sensor is lost or corrupted. Forexample, if the controller is turned off, a user may move the stopmanually along the rail, to a new position, which is not signaled to thecontroller. Accordingly, the position of the stop may be uncertain whenthe controller is powered on for a first time by a user, each time thecontroller is powered on, when the controller needs to be rebootedand/or re-initialized, when the controller has been overloaded withpower, or the like. In some cases, the controller may be programmed todrive the carriage until halted by a travel barrier, after thecontroller is powered on and before driving the stop according toentered target dimensions. The controller may determine that an end ofthe range of travel has been reached when a predefined condition issatisfied by data from a sensor. For example, the controller may assignthe current location of the motor/stop as an end position of the rangeof travel when the set point error for a time segment of the drivesequence exceeds a threshold value. Alternatively, the controller maymake the same assignment when the motor draws too much power and/or getstoo hot, among others. In any event, the controller may throttle powerto avoid a power spike and then may turn off the motor temporarily.

The controller may receive an input corresponding to the left/rightposition of the power module 212 and/or tool 54. The controller may beprogrammed to assume that the power module and tool are both near thesame end of the rail module. The left/right position may establish apolarity for travel of the stop, with travel in a “negative” directionbringing the stop closer to the power module and tool, and travel in a“positive” direction taking the stop farther from the power module.These negative and positive directions of stop travel may be correlatedwith the opposing rotational directions of the motor, such that thecontroller sends drive signals for the correct rotational direction tothe motor.

External calibration involves measurement by a user of an actualdistance from the stop to the tool, for a set point of the stop, andcommunicating the measured actual distance to the controller. Thecontroller then may offset the set point to correspond to the measuredactual distance. In the prior art, external calibration may involve atleast two set points of the stop, to determine the scale factor and theactual distance from the stop to the tool. For example, the two setpoints may be near opposite ends of the range of linear travel, todetermine two actual positions of the stop with respect to the tool. Thelinear distance between the two actual positions may be correlated torotary travel of the motor to drive the stop between the actualpositions, to calculate a scale factor. However, the internalcalibration described above enables external calibration to be performedwith only one external measurement. Accordingly, internal calibrationmay increase the accuracy and reduce the time and the length of materialneeded for external calibration.

The actual distance measured provides an absolute position of the stop,along a measurement axis, relative to the tool. Measurement of theactual distance may be performed with any suitable measuring device,such as a tape measure, calipers, an optical measuring device, or thelike, and may be carried out manually or automatically. The actualdistance may be measured without the aid of a workpiece or may bemeasured by processing a workpiece that is abutted with the stop andthen measuring a dimension of the processed workpiece. For example, theworkpiece may be abutted with the stop and then cut by a saw and thelength of the cut workpiece measured with a tape measure. The actualposition of the stop may be communicated by a user who measures theactual position or by a peripheral, electronic measuring device incommunication with the controller (e.g., see U.S. Provisional PatentApplication Ser. No. 61/185,553, filed Jun. 9, 2009, which isincorporated herein by reference).

The positioner may be configured to be calibrated by a user forengagement of the stop in two or more distinct configurations withworkpieces and/or for distinct configurations of a tool, among others.The performance of multiple calibrations for the same gauge system(e.g., FIG. 3) in distinct configurations is exemplified by a saw-basedsystem being used to create square (right angle) and miter (oblique)cuts. The positioner may be calibrated distinctly for two or more of thefollowing configurations: (1) a square workpiece end against the stopand the saw arranged for a square cut (a “square-square” calibration fora “square-square” product), (2) a square workpiece end against the stopand the saw arranged for a miter cut (a “square-miter” calibration for a“square-miter” product; inside dimension “x”; miter key 846 in FIG. 27),(3) a mitered workpiece end against the stop and the saw arranged for amiter cut (a “miter-miter” calibration for a “miter-miter” product;inside dimension “y”; miter key 848 in FIG. 27), and/or (4) a miteredworkpiece end against the stop and the saw arranged for a square cut (a“miter-square” calibration for a “miter-square” product; insidedimension “z”; miter key 850 in FIG. 27). Accordingly, separatecalibrations may be performed by a user in conjunction with thecontroller, based on whether a square workpiece end or a miteredworkpiece end is abutted with the stop. Alternatively, or in addition,separate calibrations may be performed based on whether the saw isarranged for a square cut or a miter cut. The positioner may beconfigured to permit a user to inform the controller of the type ofcalibration being performed, such as with the use of miter keys 846-850described above in relation to FIG. 27. Alternatively, or in addition,the controller may be configured to perform any of the distinct types ofcalibrations listed above, in a preset order.

The controller may be programmed to select a calibration for use with aset point. The calibration may be selected from a set of two or moredistinct calibrations, such as any of the distinct calibrations listedabove, based on a workpiece/tool configuration communicated to thecontroller (e.g., inputted by the user). For example, the controller mayapply a square-square calibration when the controller is informed that aworkpiece is being cut to create a square-square product (or as adefault calibration), a square-miter calibration when the controller isinformed that a workpiece is being cut to create a square-miter product,and so on.

In some embodiments, the controller may be programmed to apply a setpoint according to the type of cut product (square-square, square-miter,etc.) to be generated. The controller may apply a set point distinctlyfor different types of cut configurations based on the same calibration.For example, the controller may receive a square-square calibrationvalue and a set point identified as being for a square-miter product,with the set point being a target inside dimension (x) for thesquare-miter product. Many power saws are pivotable between square andmiter configurations about a vertical pivot axis that is coplanar withthe saw's fence. Accordingly, when the saw is pivoted between square andmiter configurations, and the stop is left in the same position, theouter dimension of a square-miter product is about the same as thelength of a square-square product, but the inner dimension of thesquare-miter product is reduced according to the miter angle and theworkpiece width. For example, with a 45-degree miter, the innerdimension is reduced by the width of the workpiece relative to the outerdimension. However, the inner dimension (see miter keys 846-850 of FIG.27) may be a more common measurement, in some applications, for finishcarpenters. Accordingly, the controller may apply the set point withoutadjustment for a square-square set point and may increase (or decrease)the set point according to the width of the workpiece and/or the angleat which the miter cut is to be performed for a square-miter set point.

Alternatively, or in addition, the controller may apply a set pointdistinctly according to whether a workpiece has a square end or amitered end abutted with the stop. For example, the controller mayadjust the set point by an amount related to the width of a workpiece,if a mitered end of a workpiece is abutted with a stop and an insidedimension is communicated to the controller as a set point.Alternatively, or in addition, the controller may adjust the set pointbased, at least in part, on offset distance 634 between miter endabutment and square end abutment with the stop (see FIGS. 19 and 20).

In some embodiments, the controller may be in communication with a mitersaw. The controller may send signals to the miter saw, such as to changethe angle of the miter saw, and/or may receive signals from the mitersaw. The signals received from the miter saw may correspond to whetheror not the miter saw has performed a cut and/or an angle at which themiter saw is disposed. The controller may adjust set points based on thesignals received from the miter saw.

FIG. 32 shows an exemplary flowchart 940 for a method of driving a stopto a target position based on an entered and/or calculated targetdimension. The method steps presented in flowchart 940 may be performedin any suitable combination and in any suitable order. Also, anycombination of the method steps presented in flowchart 940 may becombined with any other method steps of the present disclosure.

A target dimension may be received by the controller, indicated at 942.The target dimension may correspond to a set point, which may bedescribed as a “stationary” set point. The controller may translate thetarget dimension into target position, which, from the perspective ofthe controller, may be a rotary target position for the encoder (and/ora driven part of the motor), based on the current rotary/linear positionand the scale factor. For example, the controller may determine thedirection of rotary travel of the encoder/motor and the amount of rotarytravel of the encoder/motor (e.g., the number of encoder marks to besensed) to place the stop at the set point.

The controller may obtain a speed profile, relative to elapsed time, fordriving the stop from the current position to the set point. The speedprofile may define an acceleration phase of increasing speed, a coastingphase of substantially constant speed, and finally a deceleration phaseof decreasing speed. Based on the speed profile, the controller maycalculate a dynamic set point (a “target point”) that is updated at theend of each time segment (e.g., each millisecond) based on the speedprofile. The target point thus progressively moves toward the“stationary” set point, according to the speed profile, and at leastsubstantially reaches the stationary set point when the speed profile iscompleted.

The controller may determine a dynamic set point or target point for thefirst/next time segment based on the stationary set point, indicated at944. More particularly, the target point may be determined based a speedprofile that is obtained based on the stationary set point.

The controller may determine a position error between the target pointand the current position, indicated at 946. The controller also maycompare the position error with a threshold error, which may correspondto the maximum permitted error before the drive sequence is terminated(i.e., aborted).

The controller may determine whether the position error exceeds thethreshold error, indicated at 948. If the position error exceeds thethreshold error, this indicates that motor operation is inefficientand/or the drive sequence is proceeding abnormally. Accordingly, nodrive signal is generated and the drive sequence may be terminated,indicated at 950, and the controller then may pause, indicated at 952,and then return to the start of the method, to receive another targetdimension and/or start signal, indicated at 942. Termination of thedrive sequence and then pausing before executing another drive sequence,may include turning off the motor temporarily, that is, supplyingsubstantially no drive signals and/or power to the motor for a timesegment (such as a preset pause interval) before resuming operation ofthe motor. If the error does not exceed the threshold, the controllermay calculate a drive signal based on the error, indicated at 954. Thecontroller may utilize any suitable feedback algorithm to calculate thedrive signal.

When no power is supplied to the motor, the stop may go slack, meaningthat the motor is no longer working to control the position and speed ofthe stop. Accordingly, a user may slide the stop readily when the motoris turned off.

The controller may determine/obtain a measured speed, which maycorrespond to a rotary speed of the encoder/motor and/or a linear speedof the stop, based on position signals from the encoder, indicated at956. The controller also may compare the drive signal, which may beassociated temporally with the measured speed, with a limit, todetermine, indicated at 958, whether the drive signal exceeds the limit,which may be a speed-based limit. More particularly, the limit may beconstant or may vary at least once with the speed measured, for example,increasing with the speed, such as linearly or stepwise. If the drivesignal exceeds the limit, the drive signal may be reduced to create areduced drive signal, indicated at 960. In some embodiments, the drivesignal may be reduced in correspondence with the limit, such as set thevalue of the drive signal to the limit for the speed. In any event, thereduced drive signal may be communicated to the motor, indicated at 962.As a result, the drive signal may be throttled, which, in turn,throttles the amount of power supplied to the motor. This strategy ofpower throttling may provide a “software spring” with substantialbenefits over relying only on a threshold error to indicate problems(jams, blockages, etc.) for which the drive sequence should beterminated, because the use of a threshold error may not provide a rapidenough response to potential problems. The benefits of power throttlingmay include less damage to the motor caused by excessive power usage,improved safety provided by a more rapid response to potential injurysituations (such as when a hand gets jammed), a smoother drive sequence,an ability to drive the stop through a region of its travel path (e.g.,a region of higher friction) where travel is hampered and withoutgenerating a power spike, fewer power overloads that require acontroller restart, and the like. If, instead, the drive signal does notexceed the limit, the drive signal may be communicated to the motorwithout any reduction, also indicated at 962.

The controller may receive one or more position signals from the encoderat the end of the time segment, indicated at 964. The position signalsmay be used to determine the target point for the next time segment,indicated back at 944, to close the loop.

The method shown in FIG. 32 may be utilized to perform an internalcalibration of the positioner, to determine a scale factor. Wheninternal calibration is initiated by the controller, the controller maynot have accurate position data for the current carriage/stop position.Accordingly, the controller may be programmed to drive the carriage stopaccording to set points that are outside the predefined range of travel,to ensure that the carriage is driven to each of the travel barriers.

The controller may provide a proximal set point corresponding to travelof the carriage/stop for a distance greater than the predefined range oftravel in a negative direction (i.e., toward the tool), and a distal setpoint corresponding to travel of the carriage/stop for a distancegreater than the predefined range of travel in a positive direction(i.e., away from the tool). When carriage motion is blocked by contactwith each of the proximal and distal travel barriers (before theproximal and distal set points are reached), the drive throttlingmechanism may function to protect the motor and the electronics untilthe threshold error is exceeded and the drive sequence is terminated.After the drive sequence is terminated by contact with one of the travelbarriers, the controller then may provide the other set point andcontrol driving the carriage/stop to the other travel barrier. In anyevent, the controller may determine a number of position signals (e.g.,encoder pulses) generated when the carriage/stop is driven from onetravel barrier to the other travel barrier. A ratio may be calculatedusing the number of position signals and the range of linear travel.

FIG. 33 shows a flowchart 980 of another exemplary method that maysupplement or replace portions of the method of FIG. 32. The method ofFIG. 33 may be performed with a positioner that includes a temperaturesensor. The temperature sensor may measure a temperature associated withthe motor and communicate temperature signals to the controller,indicated at 982. The controller may calculate a drive signal, indicatedat 954, as in the method of FIG. 32.

The controller may receive a temperature signal and compare thetemperature signal to a threshold, indicated at 984. If a value of thetemperature signal exceeds the threshold, the controller may reduce thedrive signal, indicated at 986, and then communicate the reduced drivesignal to the motor. In some embodiments, the controller may reduce thevalue of the drive signal in correspondence with a difference betweenthe value of the temperature signal and the threshold. Accordingly,values of drive signals may be reduced by increasing amounts as thetemperature of the motor rises, to supply decreasing amounts ofelectrical power to the motor as the motor tends toward overheating. Insome embodiments, the threshold may be a first threshold, and thecontroller may at least substantially terminate communication ofeffective drive signals (that drive the motor) if the temperature signalexceeds a second threshold that is greater than the first threshold. Asan example, for illustration only, the motor may be rated to operate attemperatures of up to 80° C. When the motor reaches 60° C., thecontroller may begin to throttle power to the motor by reducing thevalues of drive signals. If the temperature continues to rise towards80° C., the controller may increasingly throttle power by reducing thevalues of drive signals further. When the temperature reaches 80° C.,the controller may stop supplying the motor with power, to let the motorcool down and avoid motor damage.

FIG. 34 is a flowchart 1010 of another exemplary method that maysupplement or replace portions of the methods of FIGS. 32 and 33. Themethod of FIG. 34 may be performed with a positioner that includes anelectrical sensor that senses an electrical parameter of power suppliedto the motor, such as electrical current drawn by the motor. Theelectrical sensor may measure a current drawn by the motor and maycommunicate electrical current signals to the controller, indicated at1012. The controller may calculate a drive signal, indicated at 954, asin the method of FIG. 32.

The controller may receive an electrical current signal and compare thevalue of the current signal to a threshold, indicated at 1014. If thevalue of the current signal exceeds the threshold, the controller mayreduce the value of the drive signal, indicated at 1016, and thencommunicate the reduced drive signal value to the motor. In someembodiments, the controller may reduce the value of the drive signal incorrespondence with a difference between the electrical current signaland the threshold. Accordingly, the values of drive signals may bereduced by increasing amounts as the current drawn by the motor rises,to supply decreasing amounts of electrical power to the motor. In someembodiments, the threshold may be a first threshold, and the controllermay at least substantially terminate communication of effective drivesignals (that drive the motor) if the electrical current signal exceedsa second threshold that is greater than the first threshold.

VI. EXAMPLES

The following examples describe selected aspects and embodiments of thepresent disclosure, particularly additional aspects of exemplary gaugesystems and methods of using the gauge systems. These examples and thevarious features and aspects thereof are included for illustration andare not intended to define or limit the entire scope of the presentdisclosure.

Example 1. Exemplary Gauge System with Saw

This example describes another exemplary embodiment 1100 (hereinafter,saw system 1100) of gauge system 50; see FIGS. 35-47.

FIG. 35 shows saw system 1100 arranged generally as shown in FIG. 3 forsaw system 180. Saw system 1100 is a modified version of saw system 180(see FIG. 3) and may contain any combination of the components alreadydescribed above for saw system 180 (and/or gauge system 50), but with anumber of modifications and additions. First, saw system 1100 mayutilize latches, such as draw latches 1102, to attach power module 212to beam 215. The draw latches may replace fasteners 254 (e.g., see FIGS.8 and 9). Second, saw system 1100 may include distinct bracketassemblies 1104 that mount beam 215 to saw stand 182. Bracket assemblies1104 may be utilized in place of or in addition to bracket assemblies214 (e.g., see FIGS. 28 and 29). Third, saw system 1100 may (or may not)include an accessory support leg 1106 on which beam 215 may be mounted.Fourth, saw system 1100 may incorporate a stop assembly 1108 that isconfigured for use with crown molding. Stop assembly 1108 may replacestop assembly 326 or 690, among others (e.g., see FIGS. 5 and 21-23).

FIG. 36 shows power module 212 attached to beam 215 with latches 1102.Each latch may include a cam lever 1109 with an over-center action thatretains the latch in a closed position on the beam until urged into theopen position by a user. Each latch may be described as a clamp (or amount) that is adjustable between open and closed positions. In the openposition, the latch may be received on beam 215, and in the closedposition, the latch may be engaged with beam to restrict removal and/ormotion of the latch with respect to the beam. Latches 1102 may have thesame structure, as shown here, to permit the same latch to be attachedand used on opposing sides of the power module, or the latches may havedistinct structure on opposing sides.

FIG. 37 shows rightward latch 1102 at elevation in a closed position onbeam 215. An open position of latch 1102 is indicated in phantomoutline. In this view, an end cap 1110 (see FIG. 36) has been removedfrom the end of the beam to simplify the presentation. Latches 1102 eachmay define a plurality of openings 1112 to receive fasteners 1114, suchas screws. The fasteners may attach the latches to power module 212, onopposing sides (e.g., left and right side walls) of housing 760 of thepower module.

Latch 1102 may utilize a pair of jaws, such as a movable jaw 1116 and afixed jaw 1118, to provide attachment to beam 215. The jaws may bereceived on opposing ridges 404, 406 of the beam, with flanges 1120,1122 of the jaws received in channels 390, 392 of beam 215. The jawsthus may be described as forming respective hooks that hook the latch(and the power module) onto the beam.

FIGS. 38A and 38B show respective exploded and assembled views of latch1102 taken from an inner side of the latch that faces power module 212.The latch is disposed in the open position in FIG. 38B. Latch 1102 mayincorporate a fixed member 1124 forming fixed jaw 1118, a slidablemember 1126 forming movable jaw 1116, and a cam member 1128 disposedbetween members 1124, 1126.

Fixed member 1124 may be secured to the power module (see FIG. 37) todefine a cavity or track 1130 that guides linear motion of slidablemember 1126 along an axis 1132. The fixed member also may form a boss1134 received in a horizontal slot 1136 defined by slidable member 1126,to further guide the linear motion of the slidable member. In any event,reciprocative linear motion of member 1126 opens and closes the jaws ofthe latch.

Cam member 1128 may be pivotable about its central axis to adjust thejaws between open and closed positions. The cam member may provide aneccentric projection 1138 that is received in a vertical slot 1140defined by slidable member 1126. Accordingly, rotation of the cam memberrepositions eccentric projection 1138 along slot 1140, which drivesslidable member 1126 along axis 1132. The cam member may provide agraspable handle 1142, which may function as part of cam lever 1109,which permits the cam member to be rotated manually, to open and closethe latch. Projection 1138 and slot 1140 may be arranged to provide theover-center action offered by cam lever 1109.

FIGS. 39 and 40 show how latches 1102 may be received on and closedagainst beam 215 of rail module 210. In FIG. 39, power module 212 isviewed from the bottom and has been mated with rail module 210, toengage shaft 256 with a pulley mounted in the rail module. At thispoint, power module 212 may be disposed in a skewed position, as shown,that provides sufficient clearance for both latches 1102 to be receivedon beam 215. The power module then may be pivoted, indicated at 1150,into alignment with the beam. FIG. 40 shows power module aligned withbeam 215 and with both latches 1102 closed, indicated by arrows at 1152,against beam 215. The latches may stabilize the power module on the railmodule by restricting pivotal motion of the body of the power module asshaft 256 is rotated, and by preventing upward motion of the powermodule, thereby blocking any bouncing of the power module on the railmodule, which could uncouple shaft 256 from the pulley.

FIG. 41 shows bracket assembly 1104 for connecting beam 215 to a baseframe, such as a saw stand. Bracket assembly 1104 may include an upperbeam mount 1160 and a lower beam mount 1162. Upper beam mount 1160 maybe utilized to mount beam 215 on the bracket assembly. Lower beam mount1162 may be utilized to mount bracket assembly 1104 on a beam of thebase frame (e.g., beam 188 of the saw stand in FIG. 3). Each beam mountmay be described as a clamp. The bracket assembly also may provide ashelf 1164 on which workpieces may be placed and supported. Shelf mayproject forward (at least generally toward the user) from upper beammount 1160, and thus forward from beam 215 when the beam is mounted toupper beam mount 1160.

FIG. 42 shows an exploded view of bracket assembly 1104. The bracketassembly may include upper and lower T-supports 1166, 1168. TheT-supports may be inverted relative to one another. Each T-support mayinclude a leg 1170 projecting from a head 1172. T-supports 1166, 1168may be adjustably connected to one another by a yoke 1174 that receiveslegs 1170. Each leg may slide axially and pivot in yoke 1174 until fixedin position by set screws 1176. Accordingly, bracket assembly 1104 maypermit adjustment of the relative positions of the beam mounts, bychanging their relative heights (vertical spacing), lateral positions,longitudinal positions, and/or angular dispositions. Thus, bracketassembly 1104 may permit rail module 210 and shelf 1164 to be adjustablydisposed to provide alignment with various configurations of tools, toolfences, tool decks, etc.

Upper and lower beam mounts 1160, 1162 may be attached to heads 1172 ofT-supports 1166, 1168, respectively. The upper beam mount may beattached with fastener assemblies 1178. Slots 1180 defined by head 1172may permit the upper beam mount to be secured over a range of positionsalong the head. Lower beam mount 1162 may be attached with self-tappingscrews 1182 received in any of a series of apertures 1184 arranged alongthe head of T-support 1168.

Lower beam mount 1162 may be formed by a pair of jaw members 1186, 1188.Each jaw member may supply at least one contoured surface 1190 forcontact with a side of the beam. Each contoured surface may be wavy orsinuous in profile, which may enable the lower beam mount to mate withbeams of different cross-sectional shape (e.g., for use with tool standsfrom different manufacturers). In some embodiments, each contouredsurface may form at least two notches arranged generally along avertical axis relative to one another. Each jaw member may be shaped tobe received on the head of T-support 1168 and to project below the headon opposing sides thereof. In exemplary embodiments, each jaw member maybe generally M-shaped. The jaw members may be driven toward each other,prior to placement of screws 1182, using an assembly of a threaded rod1192, washers 1194, and nuts 1196. The rod may be positioned over thecentral fold of each jaw member, and washers 1194 engaged with ends ofthe jaw members by advancement of nuts 1196 toward one another. Once adesired engagement of the frame beam is attained, screws 1182 may beinstalled to fix the jaw members to lower T-support 1168.

FIG. 43 is a side view of upper beam mount 1160 attached to beam 215.Beam mount 1160 may form a receiver for dovetail projection 408 of thebeam and may opposingly engage the dovetail projection. The upper beammount may include a base 1200 and an adjustable member 1202 in threadedengagement with the base. The base may, for example, be a bent platethat forms an elbow which is complementary to a ridge 1206 formed byprojection 408. Adjustable member 1202 may include a graspable handle orknob 1208 that allows a user to secure and release beam 215 manually.The upper beam mount may, optionally, be used without other componentsof bracket assembly 1104, to attach beam 215 more directly to a frame,such as to a platform (e.g., a table or work bench) using fastenersextending through openings of base 1200 and into the platform.

FIG. 44 shows accessory support leg 1106 in isolation from other systemcomponents. The support leg may include beam mount 1160 attached to ashelf member 1220 on which workpieces may be supported. The height ofthe support leg may be adjusted by operation of a set screw assembly1222. Use of support leg 1106 in a gauge system may be suitable whenutilizing a longer rail module 210, longer workpieces, a more spacedconfiguration of the near end of the rail module from the processingtool, or a combination thereof, among others.

FIGS. 45-47 show selected aspects of stop assembly 1108 of saw system1100. The stop assembly may be equipped with a stop foot 1230, which isshown here abutted with a miter-cut end 1232 of a piece of crown molding1234. Stop foot 1230 may include a stop plate 1236 connected to a stopbar 1238 and forming a transverse fence to abut miter-cut end 1232 (or asquare-cut end) of the crown molding, such as a tip 1240 of themiter-cut end (see FIG. 47). Stop plate 1236 may be attached, at itsbase, to a ledge 1242 projecting from an abutment surface of the stopplate, toward the crown molding and thus generally toward the origin ofthe measurement axis. Ledge 1242 may support miter-cut end 1232 andparticularly tip 1240.

Stop foot 1230 also may be equipped with a lateral fence 1244 connectedslidably to stop plate 1236, for motion along a transverse axis that isorthogonal to the measurement axis. The lateral fence may be fixed inposition at a selected site along the transverse axis by operation of aset screw 1246. The spacing of lateral fence 1244 from beam 215 may beindicated by a dimension scale 1248 formed on the face of the stopplate. Accordingly, an effective width of crown molding 1234, measuredparallel to the horizontal transverse axis of the system, may be readfrom the dimension scale.

FIG. 46 shows how crown molding 1234 may be situated with respect tostop foot 1230 and beam 215. Crown molding generally is designed to forma decorative border around the ceiling of a room by covering theinterface region where the walls meet the ceiling. An exemplarystructure for crown molding is presented in FIG. 46, with the crownmolding upside down relative to how it is typically installed. The crownmolding may have a decorative outer surface 1260 that faces into theroom and an inner surface 1262 that faces the wall and the ceiling atthe interface region. The inner surface may include a wall flat 1264that abuts the wall when installed, a ceiling flat 1266 that abuts theceiling, and an intermediate region 1268 that is spaced from the walland ceiling to form a cavity adjacent the interface region when thecrown molding is installed. The crown molding may be disposed at aspring angle 1270, namely, the angle formed between the crown moldingand the wall, when installed. Exemplary spring angles include 38, 45,and 52 degrees, among others.

The crown molding may be cut while lying flat or propped at an angle. Ifcut while lying flat, the saw may be pivoted about a horizontal axis toangle the saw for a non-vertical cut. If while propped at an angle, thecrown molding may be propped up at its spring angle, except upside down,as shown in FIG. 46. Also, the saw may be pivoted about a vertical axisto angle the saw for a vertical cut oriented obliquely to the long axisof the crown molding. Stop foot 1230, and particularly ledge 1242 andlateral fence 1244, may hold the end of a piece of crown molding at itsspring angle against beam 215 while performing a miter cut, with ceilingflat 1266 supported, in part on ledge 1242, and wall flat 1264 abuttedwith beam 215. Alternatively, or in addition, a user may use a lateralfence disposed elsewhere along a saw system and/or may manually supportthe crown molding against beam 215 at the spring angle.

Example 2. Exemplary Miter Compensation for Crown Molding

This example describes illustrative miter offsets that may be applied,by the saw systems disclosed herein, to entered target lengths forpieces of crown molding; see FIGS. 48-53.

FIG. 48 shows a somewhat schematic, sectional view of a portion of aroom 1278 taken through walls (shown hatched) toward the ceiling, withpieces of crown molding 1280-1286 installed to cover a junction regionbetween the walls and the ceiling. Prior to cutting and installation ofpieces 1280-1286, a worker generally measures corner-to-corner distancesfor the walls at the interface region to generate a cut list composed ofa set of target lengths for pieces of crown molding to be cut. (Theworker also may measure the angle of each corner (e.g., with an anglefinder), to allow determination of a miter angle at which each cutshould be made.) To simplify the presentation, each corner-to-cornerdimension is the same, and is labeled as “d” in FIG. 48. Eachcorner-to-corner distance is the target dimension for a wall side 1288of a cut product (e.g., piece 1280). However, the target dimension for aceiling side 1290 of the same cut product may be shorter, longer, or thesame as the target dimension for wall side 1288, based on theorientation and angle of the miter cuts at the ends. For example, thewall-side length (the “long point” or the greatest axial dimension) ofpiece 1280 is greater than the ceiling-side length (the “short point” orthe smallest axial dimension); the wall-side and ceiling-side lengths ofeach of pieces 1282 and 1286 are the same (if the miter angles are thesame); and the wall-side length (the short point) is less than theceiling-side length (the long point) of piece 1284. Therefore, the walldimensions measured by a worker may need to be corrected in some casesand not others to generate cut products with the desired targetdimensions on both wall and ceiling sides of each cut product.

FIG. 49 shows in schematic form an exemplary saw system 1300 including apositioner 1302 and a miter saw 1304. Positioner 1302 may include a rail1306 and a stop 1308 driven back and forth along the rail and along ameasurement axis 1310. Positioner 1302 may have any of the featuresdiscloses elsewhere herein for a positioning apparatus/positioner, suchas a controller to calculate and implement miter compensations. Saw 1304may pivot about a vertical pivot axis 1312 to orient a blade 1314 of thesaw (and cutting paths thereof) at different angles with respect tomeasurement axis 1310, to provide square and miter cuts. An origin 1316of measurement axis 1310 may be defined by intersection of axes 1310 and1312. A dimension or distance (“d”) from stop 1308 to origin 1316 may bemeasured along the measurement axis. With square cuts on both ends,distance “d” measured by the system generally corresponds to the enteredtarget dimension of a product to be cut from a workpiece. However, withmiter cuts, distance “d” may correspond to a modified form of theentered target dimension, as described below.

FIG. 50 shows saw system 1300 arranged to cut a pre-cut piece 1317 ofcrown molding to generate cut piece 1280, which will extend from oneinside corner to another in room 1278 of FIG. 48. Wall side 1288 of thecrown molding may be disposed near or intersecting measurement axis1310, while ceiling side 1290 may be spaced from the measurement axis bythe effective (horizontal) width of the crown molding as supported atthe spring angle against rail 1306. Since wall side 1288 extends to stop1308 and substantially through origin 1316, no application of a miteroffset by the positioner is needed.

FIG. 51 shows saw system 1300 arranged to saw pre-cut piece 1317 togenerate cut piece 1282, which will extend from an inside corner to anoutside corner in room 1278 of FIG. 48. Wall side 1288 extends to stop1308, so no application of a miter offset by the positioner is needed.

FIG. 52 shows saw system 1300 arranged to saw pre-cut piece 1317 togenerate cut piece 1284, which will extend from one outside corner toanother in room 1278 of FIG. 48. Wall side 1288 does not extend to stop1308 because ceiling side 1290 is longer than the wall side at amiter-cut end 1318 of the stock piece, which causes the miter-cut end tospace wall side 1288 from stop 1308. Accordingly, the saw system needsto apply a miter offset 1320. In particular, a controller of the systemmay determine and apply an appropriate miter offset, for addition to (orsubtraction from) target dimension “d,” based on an effective width 1322(“w”) of the crown molding and an angle 1324 formed by miter-cut end1318. For example, the controller may calculate the miter offset aswidth 1322 multiplied by the tangent of miter angle 1324. Alternatively,the miter angle may be defined as 90 degrees minus angle 1324, in whichcase width 1322 would be divided by the tangent of the miter angle todetermine the miter offset. In any event, a worker may determine asuitable value for the miter angle using, for example, an angle finder.A value for a corner angle may be measured with the angle finder, thevalue halved, and then used as the miter angle directly or subtractedfrom 90 degrees to obtain the miter angle.

More generally, for any miter compensation, an angle value received bythe controller and/or entered by a user may be related to the miterangle: the angle value may be the miter angle for one or both ends ofthe product or may allow the controller to determine the miter anglebased on the angle value (e.g., by dividing by two, subtracting theangle value from 90 degrees, or a combination thereof, among others).

FIG. 53 shows saw system 1300 arranged to saw pre-cut piece 1317 togenerate cut piece 1286, which will extend from an outside corner to aninside corner in the room of FIG. 48. As in FIG. 52, wall side 1288 isnot abutted with stop 1308, so the system needs to apply miter offset1318. As for piece 1284, a controller of the system may determine andapply an appropriate miter offset to add to entered target dimension “d”based on an effective width of the crown molding and an angle entered,received, or determined (including assumed by default), whichcorresponds to the miter angle of the miter-cut end adjacent stop 1308.

Example 3. Exemplary Miter Compensation for Casing Molding

This example describes illustrative miter offsets that may be applied toentered target lengths for casing molding by the saw systems disclosedherein; see FIGS. 54-57. The principles disclosed in this Example alsoor alternatively may be applied to miter compensation for baseboards.

FIG. 54 shows a somewhat schematic view of a wall 1340 defining adoorway 1342 framed with pieces of casing molding 1344-1348. Inparticular, the left jamb of doorway 1342 is covered by left piece 1344,the lintel by top piece 1346, and the right jamb by right piece 1348.Before cutting and installation of pieces 1344-1348, a worker maymeasure the dimensions of the doorway. The dimensions adjacent the leftjamb, lintel, and right jamb are designated in FIG. 54 as “x,” “y,” and“z,” which are the target inside dimensions or short points for a doorside (or inner side) 1350 of pieces 1344-1348, respectively. The targetoutside dimensions or long points for an opposing wall side (or outerside) 1352 of pieces 1344-1348 are different from their respectivetarget inside dimensions.

FIG. 55 shows saw system 1300 arranged to cut a stock piece 1354 ofcasing molding to generate cut piece 1344 for the left jamb of thedoorway. The stock piece may be arranged to place a shear cut: stockpiece 1354 may be situated with prospective outer side 1352 adjacentrail 1306 and with prospective inner side 1350 spaced from rail 1306.Accordingly, outer side 1352 is disposed at least substantially on ornear measurement axis 1310, while inner side 1350 is spaced from axis1310 by a width 1356 of stock piece 1354. As a result, the enteredinside dimension, “x,” may need to be corrected for a miter offset 1358adjacent origin 1316, to produce the desired outer or outside dimensionfor cut piece 1344 along outer side 1352.

FIG. 56 shows saw system 1300 arranged to cut a pre-cut piece 1359 ofcasing molding to generate cut piece 1346 for the lintel of the doorway.Pre-cut piece 1359 may be situated to place a shear cut as in FIG. 55.As a result, the entered inside dimension, “y,” may need to be correctedfor two miter offsets 1360, 1362, adjacent stop 1308 and origin 1316,respectively, to produce the desired outer dimension for cut piece 1346along outer side 1352.

FIG. 57 shows saw system 1300 arranged to cut a pre-cut piece 1359 ofcasing molding to generate cut piece 1348 for the right jamb of thedoorway. Pre-cut piece 1359 may be situated as in FIG. 56, but to placea square cut. As a result, the entered inside dimension, “z,” may needto be corrected for a miter offset 1364 adjacent stop 1308, to producethe desired outer dimension for cut piece 1348 along outer side 1352.

The target position of a stop for a target length adjusted for at leastone miter cut may be calculated as follows for the three types ofmitered products described in this Example, with theta being the miterangle and having a value of zero for a square cut:Target position (adjusted)=targetlength+tan(theta)*width+[x/y]-offset;  (1)ORTarget position (adjusted)=targetlength+2*tan(theta)*width+z-offset.  (2)In other words, one miter offset (tan(theta)*width) may be applied for“x,” and “z” products and two miter offsets (2*tan(theta)*width) for “y”products. The [x/y]-offset and the z-offset represent additional,optional offsets (usually set to zero) that may be set by a user whenperforming the corresponding type of miter cut. This is in case, forexample, the saw is slightly offset when turned in one directionrelative to the other, such as slightly offset when turning to the left(x and y cuts), relative to when turning to the right (z cuts), or viceversa.

Example 4. Exemplary Algorithms for Tangent Approximation

This example describes exemplary algorithms for calculating anapproximate value for the tangent of a selected angle.

The controller may calculate one or more suitable miter offsets to applyto an entered and/or calculated target dimension, to obtain an adjusteddimension, as described elsewhere herein, such as in Examples 2 and 3,among others. The calculation for each miter offset generally involvesmultiplying or dividing the width of a workpiece by the tangent of amiter angle formed or to be formed at an end of the workpiece or aproduct thereof. Either multiplication or division is used for thecalculation based on how the miter angle is defined. If a square cut isdefined as having a miter angle of zero degrees, multiplication is used,while if a square cut is defined as having a miter angle of 90 degrees,division is used. Also, since the sine of an angle divided by its cosineyields the angle's tangent, the width may be multiplied or divided bythe tangent of the miter angle by multiplying (or dividing) by the sineof the miter angle and dividing (or multiplying) by the cosine of themiter angle. If the miter angle is 45 degrees, the width is equal to themiter offset, since the tangent of 45 degrees is one. In any event, thetangent of the miter angle may be entered by a user, may be obtainedfrom a look-up table stored in the controller, and/or may beapproximated using an algorithm executed by the controller.

The tangent of an angle may be expressed as a Taylor series. A Taylorseries is the sum of an infinite number of terms, with the terms gettingprogressively smaller, to provide convergence to some regular value. ATaylor polynomial, containing a finite number of terms taken from thebeginning of a Taylor series, may provide an approximation to theregular value. However, the Taylor series for tangent may be difficultto use in a tangent calculation. Instead, Taylor polynomials forapproximating sine and cosine may be utilized by the controller todetermine an approximate tangent value. Accordingly, the controller mayevaluate terms of respective Taylor polynomials generated fromcorresponding Taylor series for sine and cosine. Moreover, thecontroller may be programmed to execute a loop iteratively, where one ofthe terms of the Taylor polynomials for sine and/or cosine is determinedwith each execution of the loop.

The conventions used below are as follows: (1) X^Y means X raised to theY power, so X-squared would be written as X^2; (2) X! means X factorial,so 4! would be 4*3*2*1=24; (3) X % Y means X modulo Y, where X isdivided by Y and the remainder is given as the result. The most commonusage of the modulo function is X % 2, which is 0 for even values of X,and 1 otherwise.

The Taylor series for sine and cosine are as follows:sine=x−(x^3)/3!+(x^5)/5!−(x^7)/7!+(x^9)/9!− . . .cosine=1−(x^2)/2!+(x^4)/4!−(x^6)/6!+(x^8)/8!− . . .

An algorithm for generating approximations of sine, cosine, and tangentis as follows:

Set up: (1) given an angle, X, in degrees, convert X to radians; (2) seta temporary variable, T, to 1; (3) set Sin and Cos variables to 0; and(4) set a counting variable, n, to 0.

Begin Cycle: (1) add T to Cos, so Cos=1; (2) add 1 to n, so n=1; (3)multiply T by (X/n), so T=X/1; (4) add T to Sin, making Sin=X; (5)multiply T by −1, so for the next cycle, the additions to Sin and Cosare subtractions; (6) add 1 to n, so n=2; (7) multiply T by (X/n), soT=(X^2)/2!; (8) go back to Begin Cycle, until the accuracy issufficient.

Since Tan=Sin/Cos, approximate values for all three functions have beendetermined.

Computer code in the C language follows for performing the steps listedabove. The cycle may be executed any suitable number of times, such aseight times (two steps per cycle with eight cycles gives a limit on thecounting variable of 16). The code is very compact and takes up verylittle storage space in a controller where such space is limited.

Code 1:

float tangent(float degrees) {    float sine = 0.0, cosine = 0.0, temp =1.0;    char i = 0;    degrees *= 0.0174532925;    for(i=0; i<16; i++)   {       if(i%2 == 0)       {          cosine += temp;       }      else       {          sine += temp;          temp *= −1;       }      temp *= degrees / (i+1);    }    return (sine / cosine); }The following code (Code 2) is functionally identical to Code 1, but has16 fewer additions [from (i+1)], 16 fewer divisions [from (i % 2)], but16 more bit- and operations (which are faster than modulo ones, but inthis case have the same effect, returning one when odd, zero when even).

Code 2:

float tangent(float degrees) {    float sine = 0.0, cosine = 0.0, temp =1.0;    char i;    degrees *= 0.0174532925;    for(i=1; i<=16; i++)    {      if( (i & 0x01) == 1)       {          cosine += temp;       }      else       {          sine += temp;          temp *= −1;       }      temp *= degrees / i;    }    return (sine / cosine); }

Example 5. Selected Embodiments

This example describes selected aspects and embodiments of the presentdisclosure as a set of indexed paragraphs.

1. A gauge system for workpiece processing using a tool having a site ofaction, comprising: (A) a stop configured to be abutted with workpieces;(B) a drive assembly capable of driving the stop back and forth todifferent separations from the site of action; and (C) a controllerprogrammed (i) to receive and/or calculate a target dimension of aproduct to be generated from a workpiece with the tool and (ii) tocontrol the drive assembly such that the stop is driven to a targetposition spaced from the site of action according to the targetdimension, thereby allowing the workpiece to be modified by the tool,with the workpiece disposed against the stop at the target position, togenerate the product,

wherein, optionally, the gauge system also comprises a rail, wherein thestop is connected to the rail, and wherein the stop is driven back andforth along the rail.

2. The gauge system of paragraph 1, further comprising a saw machine asthe tool.

3. The gauge system of paragraph 1 or 2, wherein the saw machine iselectrically powered.

4. The gauge system of paragraph 2 or 3, wherein the saw machineincludes a saw blade defining a cutting path, and wherein the saw bladeis pivotable with respect to the rail about a pivot axis.

5. The gauge system of paragraph 4, wherein the saw machine includes amiter saw including a saw blade that is pivotable with respect to therail about a vertical pivot axis.

6. The gauge system of paragraph 5, wherein the rail includes a frontwall defining a vertical plane, and wherein the vertical planeintersects or nearly intersects the vertical pivot axis.

7. The gauge system of paragraph 1, wherein the front wall is forabutment with workpieces.

8. The gauge system of any preceding paragraph, wherein the railprovides a longitudinal fence to abut a side of the workpiece.

9. The gauge system of any preceding paragraph, wherein the stop isdriven back and forth along a measurement axis that intersects the siteof action to define an origin, and wherein separations of the stop fromthe site of action are measured along the measurement axis from theorigin.

10. The gauge system of paragraph 9, wherein the measurement axisextends adjacent to or on a front surface of the rail.

11. The gauge system of paragraph 9 or 10, wherein the tool is pivotableabout a pivot axis with respect to the rail, and wherein the pivot axisintersects the measurement axis.

12. The gauge system of any preceding paragraph, wherein the tool issupported by a frame, wherein the frame includes a fence, and whereinthe fence and the rail include respective workpiece abutment surfacesthat are substantially coplanar with one another.

13. The gauge system of any preceding paragraph, wherein the controlleris programmed to situate the stop at measured distances from the site ofaction of the tool along a measurement axis, and wherein the raildefines a longitudinal axis that is parallel to the measurement axis.

14. The gauge system of any preceding paragraph, wherein the railextends horizontally.

15. The gauge system of any preceding paragraph, further comprising thetool, wherein the tool is connected to the rail.

16. The gauge system of paragraph 15, further comprising a framesupporting the rail and the tool.

17. The gauge system of paragraph 16, wherein the frame also supportsthe drive assembly and the controller.

18. The gauge system of paragraph 16 or 17, wherein the frame includes aplurality of legs.

19. The gauge system of any of paragraphs 16-18, wherein the frameincludes a horizontal beam.

20. The gauge system of paragraph 19, wherein the horizontal beamsupports the rail, the tool, or both.

21. The gauge system of any of paragraphs 16-20, wherein the frameincludes at least one extendable arm.

22. The gauge system of paragraph 21, wherein the frame includes a beamand a pair of extendable arms that are storable in the beam.

23. The gauge system of any of paragraphs 16-22, further comprising oneor more bracket assemblies that attach the rail to the frame, wherein,optionally, each bracket assembly includes an upper connector thatmounts the rail on such bracket assembly and a lower connector thatmounts such bracket assembly on the frame, wherein, optionally, at leastone of the upper connector and the lower connector is a clamp, wherein,optionally, each bracket assembly is adjustable to change an angularorientation of the upper and lower connectors with respect to oneanother, wherein, optionally, each bracket assembly is adjustable tochange a spacing along the rail of the upper connector and the lowerconnector from one another.

24. The gauge system of any of paragraphs 16-23, wherein the frameincludes a beam, and wherein the one or more bracket assemblies aremounted on the beam, and wherein the rail is mounted on the bracketassemblies.

25. The gauge system of any preceding paragraph, wherein the rail isformed by a beam, and wherein the stop moves back and forth along thebeam.

26. The gauge system of paragraph 25, wherein the beam is formed ofaluminum.

27. The gauge system of paragraph 25 or 26, wherein the beam is formedas an extrusion, and wherein, optionally, the beam has a substantiallyuniform cross section along the beam.

28. The gauge system of any of paragraphs 25-27, wherein the beam ishollow.

29. The gauge system of any of paragraphs 25-28, wherein the beam is atleast generally rectangular in cross section.

30. The gauge system of any of paragraphs 25-29, wherein the beamincludes outer walls and one or more inner walls.

31. The gauge system of paragraph 30, wherein the beam includes avertical inner wall.

32. The gauge system of paragraph 30 or 31, wherein an outer walldefines a gap extending along the beam.

33. The gauge system of paragraph 32, wherein the gap extends an entirelength of the beam.

34. The gauge system of paragraph 32 or 33, wherein the outer wallsinclude a front wall, a back wall, a top wall, and a bottom wall, andwherein the gap is defined by the back wall.

35. The gauge system of any of paragraphs 25-34, wherein the beam iscontinuous.

36. The gauge system of paragraph 35, wherein the beam is monolithic.

37. The gauge system of any preceding paragraph, wherein the driveassembly includes a motor.

38. The gauge system of paragraph 37, wherein the motor is an electricmotor.

39. The gauge system of paragraph 38, wherein the motor is a servomotor.

40. The gauge system of any of paragraphs 37-39, wherein the driveassembly includes a linkage that transmits motive power from the motorto the stop.

41. The gauge system of paragraph 40, wherein at least a portion of thelinkage is disposed inside the rail.

42. The gauge system of paragraph 40, wherein the linkage includes oneor more members that rotate with respect to the rail.

43. The gauge system of paragraph 42, wherein the linkage includes oneor more pulleys.

44. The gauge system of any of paragraphs 40-43, wherein the linkageincludes a belt.

45. The gauge system of any preceding paragraph, wherein the controllerincludes a digital processor, a user interface, a display, or anycombination thereof.

46. The gauge system of paragraph 45, wherein the user interface is akeypad.

47. The gauge system of any preceding paragraph, wherein the driveassembly and/or the controller is configured to receive line power.

48. The gauge system of any preceding paragraph, further comprising atleast one battery operatively connected to the drive assembly and/or thecontroller to supply electrical power.

49. The gauge system of any preceding paragraph, wherein the rail and/ora beam forming the rail is at least about 4, 6, 8, or 10 feet long.

50. The gauge system of any preceding paragraph, further comprising astop assembly that provides a stop, wherein the stop assembly includes abar and a foot connected to the bar, and wherein the foot forms atransverse fence configured to abut workpieces.

51. The gauge system of paragraph 50, wherein the bar and the foot areconnected pivotably to the rail.

52. The gauge system of any preceding paragraph, wherein the driveassembly includes a carriage that supports the stop.

53. The gauge system of paragraph 52, where the stop is connectedpivotably to the carriage.

54. The gauge system of paragraph 52 or 53, wherein the carriage slidesalong the rail.

55. The gauge system of paragraph 53 or 54, wherein the carriage isdisposed at least predominantly in the rail.

56. The gauge system of paragraph 53 or 54, wherein the carriage isdisposed at least predominantly on the rail.

57. The gauge system of any preceding paragraph, further comprising arail assembly that includes the rail and at least a portion of the driveassembly.

58. The gauge system of any preceding paragraph, further comprising amotor assembly forming at least a part of the drive assembly andincluding a motor.

59. The gauge system of paragraph 58, further comprising a motor boxthat includes the motor assembly.

60. The gauge system of paragraph 59, wherein the motor box alsoincludes the controller.

61. The gauge system of paragraph 58, further comprising a power moduleincluding the motor assembly and/or the motor.

62. The gauge system of paragraph 61, wherein the power module includesthe controller.

63. The gauge system of any preceding paragraph, wherein operation ofthe motor holds the stop at the target position.

64. The gauge system of any preceding paragraph, wherein the tool is asaw defining a cutting path, wherein the controller is programmed (i) toreceive a target length of a product to be generated from the workpiece,and (ii) to control operation of the drive assembly based on the targetlength such that the stop is driven to an adjusted position spaced fromthe cutting path by an adjusted length representing modification of thetarget length with at least one miter offset, to compensate for a mitercut at one or both ends of the product.

65. The gauge system of paragraph 64, wherein the controller isprogrammed to receive a width of the workpiece and an angle of the mitercut and to calculate the adjusted length using the width and the angle,and wherein, optionally, the controller is programmed to use a defaultangle of 45 degrees if the angle is not received.

66. The gauge system of paragraph 64 or 65, wherein the controllerincludes a user interface having a plurality of keys, wherein at leastone of the plurality of keys is a miter key, and wherein pressing themiter key instructs the controller to calculate an adjusted length tocompensate for at least one miter cut.

67. The gauge system of paragraph 66, wherein the miter key isassociated with a graphic representation of a miter-cut end of aworkpiece and/or product.

68. The gauge system of paragraph 66 or 67, wherein the keys include afirst miter key and a second miter key, wherein pressing the first miterkey instructs the controller to compensate for a miter cut at only oneend of the workpiece, and wherein pressing the second miter keyinstructs the controller to compensate for a miter cut at both ends ofthe workpiece.

69. The gauge system of paragraph 66 or 67, wherein pressing the miterkey once instructs the controller to compensate for a miter cut at oneend of the workpiece, and wherein pressing the miter key twice instructsthe controller to compensate for a miter cut at both ends of theworkpiece.

70. The gauge system of any of paragraphs 66-69, wherein the pluralityof keys includes a width key, and wherein pressing the width keyinstructs the controller to receive a width of the workpiece.

71. The gauge system of any of paragraphs 64-70, wherein the adjustedlength is longer than the target length.

72. The gauge system of any of paragraphs 64-70, wherein the adjustedlength is shorter than the target length.

73. The gauge system of any of paragraphs 64-72, wherein the miter cutis at 45 degrees with respect to a longitudinal axis of the workpiece,and wherein the adjusted length is the target length plus or minus awidth of the workpiece or plus or minus twice a width of the workpiece.

74. The gauge system of any of paragraphs 64-73, wherein the controlleris programmed to receive a cut list specifying target lengths for cutproducts, a width of a workpiece to be used to generate each cutproduct, and whether a miter compensation should be introduced togenerate each cut product.

75. The gauge system of any preceding paragraph, further comprising arail module and a power module, wherein the rail module includes a beamthat forms the rail and also includes a first member connected to thebeam such that rotation of the first member drives the stop back andforth along the beam, to achieve different separations of the stop fromthe site of action of the tool, wherein the power module forms at leastpart of the drive assembly and includes a motor and a second memberrotated by operation of the motor, and wherein the power moduledetachably mates with the rail module by fitting the first and secondmembers together such that the operation of the motor transmits motivepower to the stop.

76. The gauge system of paragraph 75, wherein the first member is afirst pulley, and wherein the rail module includes the first pulley anda second pulley rotatably coupled to one another by a belt.

77. The gauge system of paragraph 75 or 76, wherein the beam defines alongitudinal axis, and wherein the power module mates with the railmodule by motion orthogonal to the longitudinal axis.

78. The gauge system of any of paragraphs 75-77, wherein the powermodule mates with the rail module to form a first connection, whereinthe power module attaches to the rail module via a second connectionthat blocks rotation of a body of the power module and uncoupling of thepower module from the rail module, wherein, optionally, the power moduleincludes at least one clamp configured to form the second connection byattachment to the beam, wherein, optionally, each of the first andsecond connections is configured to be implemented manually, without theuse of tools, and wherein, optionally, the second connection is actuatedby a cam lever.

79. The gauge system of any of paragraphs 75-78, wherein the controlleris included in the power module.

80. The gauge system of any of paragraphs 75-79, wherein the powermodule and the rail module mate with one another to form a matedconnection that is rotatably driven with respect to the beam byoperation of the motor.

81. The gauge system of paragraph 80, wherein the mated connectionincludes a shaft received in a socket.

82. The gauge system of paragraph 81, wherein the shaft is a splinedshaft.

83. The gauge system of any of paragraphs 75-82, wherein the firstmember includes a pulley.

84. The gauge system of paragraph 83, wherein the pulley is mounted inthe beam.

85. The gauge system of paragraph 83 or 84, wherein the pulley is afirst pulley, wherein the rail module when mated with the power moduleincludes the first pulley and a second pulley rotatably coupled to oneanother by a belt.

86. The gauge system of any of paragraphs 75-85, wherein the controlleris included in the power module, and wherein the controller and themotor have fixed relative positions in the power module.

87. The gauge system of any of paragraphs 75-86, wherein the beam hasopposing ends, and wherein the power module is capable of operativelymating with the rail module near each of the opposing ends of the beam.

88. The gauge system of any of paragraphs 75-87, wherein the powermodule mates with the rail module from above the rail module.

89. The gauge system of any preceding paragraph, further comprising arail assembly that includes a beam forming the rail and also includes apair of pulleys and a belt that couples rotation of the pulleys to oneanother, wherein the beam includes an exterior surface and a pair ofcavities each extending transversely into the beam from the exteriorsurface, and wherein the pulleys are mounted in the cavities.

90. The gauge system of paragraph 89, wherein the beam includes wallsextending along the beam, and wherein each of the pulleys is disposed inapertures formed in two or more of the walls.

91. The gauge system of paragraph 89 or 90, wherein the beam ismonolithic.

92. The gauge system of paragraph 89 or 91, wherein the beam includeswalls extending along the beam, and wherein each cavity includes anaperture formed in a wall.

93. The gauge system of any of paragraphs 89-92, wherein each of thepulleys is disposed in apertures formed in two or more of the walls ofthe beam.

94. The gauge system of any of paragraphs 89-93, wherein each pulley isconnected to the beam with at least one bearing disposed in an apertureformed in one or more walls of the beam.

95. The gauge system of paragraph 94, wherein the one or more walls ofthe beam block motion of the at least one bearing along the beam.

96. The gauge system of paragraph 94 or 95, wherein the at least onebearing is ring-shaped.

97. The gauge system of any of paragraphs 89-96, wherein each pulley isconnected to the beam with a pair of bearings each having a fixedposition along the beam.

98. The gauge system of any of paragraphs 89-97, wherein each cavity anda corresponding pulley mounted in such cavity are coaxial with oneanother.

99. The gauge system of any of paragraphs 89-98, wherein the pulleyshave a fixed, non-adjustable spacing from one another in the beam.

100. The gauge system of any of paragraphs 89-99, wherein each pulleyhas a rotation axis that is vertical.

101. The gauge system of any preceding paragraph, further comprising arail assembly that includes a beam forming the rail and also includes apair of pulleys and a belt that couples rotation of the pulleys to oneanother, wherein the belt extends to a pair of ends, wherein the railassembly includes a belt linkage that secures the pair of ends adjacentone another to form a closed loop around the pulleys, and wherein thebelt linkage is adjustable to change a spacing of the ends relative toeach other while the ends remain secured, thereby permitting changes toa tension of the belt via its ends.

102. The gauge system of paragraph 101, wherein the beam includesopposing ends, and wherein the belt linkage is accessible for adjustmentfrom outside the beam at a position intermediate the opposing ends ofthe beam.

103. The gauge system of paragraph 101 or 102, wherein the beam hasopposing front and back sides, and wherein the belt linkage isaccessible for adjustment adjacent the back side.

104. The gauge system of any preceding paragraph, further comprising acarriage that supports the stop, wherein the rail is formed by a beamthat supports the carriage and forms an external track, and wherein thecarriage is driven along the beam guided by the external track.

105. The gauge system of paragraph 104, wherein the carriage includesone or more set screws that are adjustable to limit side-to-side play ofthe carriage on the beam.

106. The gauge system of paragraph 104 or 105, wherein the carriageslides on the beam, wherein the carriage includes a body and at leastone slide element separating the body from the beam, and wherein theslide element is configured to reduce a coefficient of friction betweenthe carriage and the beam to encourage sliding of the carriage on thebeam.

107. The gauge system of any of paragraphs 104-106, wherein the externaltrack includes a box way.

108. The gauge system of any of paragraphs 104-107, wherein the externaltrack includes a pair of channels formed on front and back sides of thebeam.

109. The gauge system of any of paragraphs 104-108, wherein the externaltrack includes a pair of flanges disposed on opposing sides of the beam,and wherein the carriage includes a pair of generally C-shaped regionsthat receive portions of the flanges.

110. The gauge system of paragraph 109, wherein the flanges aresubstantially rectangular.

111. The gauge system of any preceding paragraph, wherein the controllercontains a security code, wherein the controller, when powered off andthen back on, is programmed to go into a lockout state in which thecontroller does not execute most or all user commands, and wherein thecontroller in the lockout state is programmed to require a user to matchthe security code before the controller leaves the lockout state toexecute commands from the user without substantial restriction.

112. The gauge system of any preceding paragraph, wherein the driveassembly includes a motor, wherein the rail is formed by a beam havingopposing ends, and wherein the motor is capable of operative connectionto the stop with the motor disposed near either opposing end of thebeam.

113. The gauge system of paragraph 112, further comprising a railassembly including the beam and a first member and a second member eachmounted rotatably to the beam, wherein the motor is included in a powerhead, and wherein the power head engages the first member when the motoris operatively connected to a leftward position of the rail assembly andengages the second member when the motor is operatively coupled to arightward position of the rail assembly.

114. The gauge system of paragraph 113, wherein each member is a pulley,wherein the rail assembly includes a belt that couples rotation of thepulleys to one another, and wherein the belt couples rotation of thepulleys to reciprocative motion of the stop.

115. The gauge system of paragraph 113 or 114, wherein the rail assemblyhas a top side and a bottom side, and wherein the motor is operativelyconnectable to the rail assembly at leftward and rightward sites formedon and/or in the top side.

116. The gauge system of any of paragraphs 113-115, wherein the motor isincluded in a power module, and wherein the rail assembly defines asocket near each end that mates with the power module to coupleoperation of the motor to driven motion of the stop.

117. The gauge system of any of paragraphs 113-116, wherein thecontroller is programmed (i) to receive an input that indicates whetherthe cutting path has a leftward position or a rightward position withrespect to the rail assembly and (ii) to select rotational directionsfor operation of the motor that drive the stop toward and away from thecutting path based on whether a leftward or rightward position isindicated by the input.

118. The gauge system of any of paragraphs 112-117, further comprising apower head, wherein the motor and the controller are both contained inthe power head.

119. The gauge system of paragraph 118, wherein the power head includesa housing, and wherein the motor and the controller are disposed inand/or on the housing.

120. The gauge system of any preceding paragraph, wherein the driveassembly includes a motor, wherein the controller is programmed torestrict amounts of power supplied to the motor according to apredefined limit, and wherein the predefined limit increases at leastonce in correspondence with increased speed of the motor, therebyreducing or eliminating generation of power spikes when motion of thestop is blocked or hampered.

121. The gauge system of paragraph 120, wherein the motor assemblyincludes a sensor in communication with the controller and configured tomeasure rotary positions of a rotating part of the motor assembly, andwherein the controller is programmed to determine the speed of the motorbased on the measured rotary positions.

122. The gauge system of paragraph 120 or 121, wherein the predefinedlimit increases linearly or stepwise with the speed of the motor, and/orwherein the predefined limit and/or a slope at which the predefinedlimit changes with motor speed are both settable by a user.

123. The gauge system of any of paragraphs 120-122, wherein the motorassembly includes a sensor in communication with the controller andconfigured to measure an aspect of the motor assembly, wherein thecontroller is programmed to monitor measurements from the sensor and toturn off the motor temporarily if one or more of the measurements meet apredefined condition indicating motor inefficiency, thereby reducingdamage to the motor and improving safety for a user, and wherein,optionally, the sensor is a rotary encoder that measures movement of arotating part of the motor

124. The gauge system of paragraph 123, wherein the aspect is atemperature of the motor assembly, a position of a moving part of themotor assembly, or an electrical characteristic of motor operation.

125. The gauge system of paragraph 123 or 124, wherein the aspect is arotary position of a rotatable part of the motor assembly, and whereinthe controller is programmed to turn off the motor if measured rotationof the rotatable part deviates sufficiently from expected rotation ofthe rotatable part.

126. The gauge system of any of paragraphs 120-125, wherein thecontroller controls communication of drive signals to the motor, andwherein a value of each drive signal corresponds to an amount of powersupplied to the motor during a time segment.

127. The gauge system of any of paragraphs 120-126, wherein thecontroller is programmed to compare each drive signal value to thepredefined limit and to reduce each drive signal value before such drivesignal value is implemented to supply an amount of power to the motor,if such drive signal value exceeds the predefined limit.

128. The gauge system of any of paragraphs 120-127, wherein thecontroller is programmed to monitor data from a sensor and to turn offpower to the motor temporarily if at least a portion of the data meets apredefined condition.

129. The gauge system of any of paragraphs 120-128, wherein thecontroller is programmed to execute a drive sequence that results inplacement of the stop at the target position, and wherein the controlleris programmed to abort execution of the drive sequence before the targetposition is reached if the at least a portion of the data meets apredefined condition.

130. The gauge system of paragraph 129, wherein the controller isprogrammed to receive signals from a position sensor and to abortexecution of the drive sequence based on one or more of the signals ifsuch one or more signals meet the predefined condition.

131. The gauge system of any preceding paragraph, further comprising arail assembly including the rail, a carriage, and at least one travelbarrier, wherein the stop is supported by the carriage, wherein the stophas a range of travel along the rail, wherein at least one end of therange of travel is determined by contact of the carriage with the travelbarrier, and wherein the controller is programmed, when a currentlocation of the stop within the travel path is not certain, to drive thestop until movement of the stop is halted by the contact of the carriagewith the travel barrier, to define the current location of the stop.

132. The gauge system of paragraph 131, wherein both ends of the rangeof travel of the stop are determined by contact of the carriage withtravel barriers, and wherein the controller, when powered up at leastfor a first time, is programmed to drive the carriage until halted byeach of the travel barriers.

133. The gauge system of paragraph 131 or 132, wherein the controller isprogrammed to drive the carriage until halted by a travel barrier, afterthe controller is powered on and before driving the stop according toentered target dimensions.

134. The gauge system of any of paragraphs 131-133, wherein thecontroller is programmed to turn off the motor temporarily when thecarriage is halted by a travel barrier, and wherein, optionally, asensed position of the motor when the motor is turned off is assigned bythe controller as an end of the range of travel.

135. The gauge system of any preceding paragraph, further comprising oneor more bracket assemblies configured to mount the rail to a frame thatsupports the tool, and wherein each bracket assembly provides at leastone support surface that projects forward of the rail for contact withan underside of a workpiece such that the one or more bracket assembliesare capable of supporting the workpiece in front of the rail.

136. The gauge system of paragraph 135, wherein the bracket assemblyincludes an upper connector that mounts the rail on the bracket assemblyand a lower connector that mounts the bracket assembly on the frame.

137. The gauge system of paragraph 135 or 136, wherein the bracketassembly is adjustable to change a height of the upper connector abovethe lower connector.

138. The gauge system of any of paragraphs 135-137, wherein the bracketassembly is adjustable to move the upper connector forward and/orrearward with respect to the lower connector.

139. The gauge system of any of paragraphs 135-138, wherein the railincludes a dovetail projection, and wherein the upper connector mountsthe rail on the bracket assembly by engagement of the dovetailprojection.

140. The gauge system of any preceding paragraph, wherein the railincludes a beam having opposing ends, wherein the drive assemblyincludes a motor that supplies motive power to the stop, and wherein themotor is configured to be operatively connected to the stop near each ofthe opposing ends of the beam.

141. The gauge system of any preceding paragraph, wherein the driveassembly includes a motor, wherein the rail has opposing end regions,and wherein the motor is operatively connectable to the rail at each endregion to couple operation of the motor, from either end region, todriven motion of the stop back and forth along the rail.

142. The gauge system of paragraph 141, further comprising a railassembly and a power head, wherein the rail assembly includes a beamthat forms the rail and also includes a first member and a second membereach mounted rotatably to the beam, wherein the motor is included in thepower head, and wherein the power head engages the first member when themotor is operatively connected to a leftward position of the railassembly and engages the second member when the motor is operativelycoupled to a rightward position of the rail assembly.

143. The gauge system of paragraph 142, wherein each of the first andsecond members is a pulley, wherein the rail assembly includes a beltthat couples rotation of the pulleys to one another, and wherein thebelt coverts rotation of the pulleys to motion of the stop along thebeam.

144. The gauge system of any of paragraphs 141-143, further comprising arail assembly including the rail, wherein the rail assembly has a topside and a bottom side, and wherein the motor is operatively connectableto the rail assembly at leftward and rightward sites formed on and/or inthe top side.

145. The gauge system of any of paragraphs 141-144, further comprising apower head forming at least part of the drive assembly and including themotor, and wherein each end region of the rail includes a socket withwhich the power head mates to couple operation of the motor to drivenmotion of the stop.

146. The gauge system of any of paragraphs 141-145, wherein thecontroller is programmed (i) to receive an input that indicates whetherthe tool has a leftward position or a rightward position with respect tothe rail and (ii) to select rotational directions for operation of themotor that drive the stop toward and away from the tool based on whethera leftward or rightward position is indicated by the input.

147. The gauge system of any of paragraphs 141-146, further comprising apower head, wherein the motor and the controller are both included inthe power head.

148. A gauge system for cutting workpieces for use in miter joints,comprising: (A) a saw defining a cutting path and being pivotable abouta pivot axis to orient the cutting path for miter cuts; and (B) apositioning apparatus including a rail extending parallel to ameasurement axis that intersects the cutting path at the pivot axis todefine an origin, a stop connected to the rail and configured to abutends of workpieces, a drive assembly that drives the stop back and forthalong the measurement axis to different separations from the origin, anda controller programmed (i) to calculate a set point based on a targetlength of a product to be generated from the workpiece, a width of theworkpiece, and an angle of a miter cut at one or both ends of theproduct such that the set point corresponds to the target lengthmodified with at least one miter offset to compensate for the miter cut,and (ii) to control the drive assembly such that the stop is driven toand held at a target position spaced from the origin according to theset point, thereby enabling the saw to form a product having the mitercut and the target length.

149. A gauge system for cutting workpieces for use in miter joints,comprising: (A) a miter saw pivotable about an origin of a measurementaxis to orient the saw for performing miter cuts; and (B) a positioningapparatus including a longitudinal fence extending parallel to themeasurement axis and configured to abut sides of workpieces, atransverse fence connected movably to the longitudinal fence andconfigured to abut ends of workpieces, a drive assembly that drives thetransverse fence back and forth along the measurement axis to achievedifferent separations from the origin, and a controller programmed (i)to receive a width of a workpiece and a target length of a product to begenerated from the workpiece, (ii) to calculate an adjusted length basedon the target length and the width such that the adjusted lengthintroduces at least one miter offset to the target length to compensatefor a difference in length on opposing sides of the product caused by amiter cut at one or both ends of the product, and (iii) to control thedrive assembly such that the transverse fence is driven to and held atan adjusted position spaced from the origin according to the adjustedlength, thereby enabling generation by the saw of a product having themiter cut, and the target length and the adjusted length on opposingsides of the product.

150. A positioning apparatus to enable cutting workpieces with a mitersaw that is pivotable about an origin of a measurement axis to orientthe miter saw for performing miter cuts, comprising: (A) a railextending parallel to the measurement axis, (B) a stop connected to therail and configured to abut ends of workpieces, (C) a drive assemblythat drives the stop back and forth along the rail to differentseparations from the origin, and (C) a controller programmed (i) toreceive a width of a workpiece and a target length of a product to begenerated from the workpiece, (ii) to calculate an adjusted length basedon the target length and the width such that the adjusted lengthintroduces at least one miter offset into the target length tocompensate for a difference in length on opposing sides of the productcaused by a miter cut at one or both ends of the product, and (iii) tocontrol the drive assembly such that the stop is driven to and held atan adjusted position spaced from the origin according to the adjustedlength, thereby enabling generation by the saw of a product having themiter cut, the target length, and the adjusted length.

151. The apparatus of paragraph 150, wherein the stop provides a datumfor abutment with ends of workpieces, and wherein workpieces abuttedwith the datum and extending across a cutting path of the miter saw canbe cut to generate products.

152. A positioning apparatus to enable modification of workpieces usinga tool and with the workpieces aligned with a measurement axis having anorigin defined by action of the tool, comprising: (A) a fence moduleincluding a longitudinal fence extending parallel to the measurementaxis and a transverse fence connected to the longitudinal fence, thefence module also including a first member connected rotatably to thelongitudinal fence such that rotation of the first member in opposingrotational directions causes reciprocative motion of the transversefence along the measurement axis to achieve different separations of thetransverse fence from the origin; (B) a power module including a motorand a second member driven to rotate by operation of the motor, thepower module detachably mating with the fence module by fitting thefirst and second members together, to couple operation of the motor tomotion of the transverse fence; and (C) a controller programmed (i) toreceive a target dimension of a product to be generated from a workpiecewith the tool and (ii) to control the power module such that thetransverse fence is driven to and held at a target position that isspaced from the origin according to the target dimension, therebyallowing the workpiece to be abutted with the fence module and thenmodified by action of the tool to generate the product.

153. A method of processing a workpiece, comprising: (A) providing aworkpiece, a tool having a site of action, and a positioning apparatusincluding (i) a rail defining a longitudinal axis that is parallel to ameasurement axis intersecting the processing site, (ii) a stop, (iii) adrive assembly that drives the stop back and forth along the measurementaxis to different separations from the processing site, and (iv) acontroller connected to and programmed to control the drive assembly;(B) entering into the controller a set point representing a distancefrom an end of a workpiece to a target site along the workpiece wherethe tool will modify the workpiece; (C) instructing (commanding) thecontroller to initiate movement of the stop to a spacing from theprocessing site that corresponds to the set point; (D) disposing theworkpiece such that an end of the workpiece is engaged with the stop andthe workpiece extends along the measurement axis; and (E) modifying theworkpiece with the processing tool after the step of disposing and withthe stop at the spacing from the processing site.

154. The method of paragraph 153, wherein the step of instructingresults from the step of entering.

155. A method of processing a workpiece, comprising: (A) providing (1) atool to modify workpieces and having a site of action, and (2) apositioning apparatus connected to the tool and including (i) a rail,(ii) a stop connected to the rail and configured to be abutted withworkpieces, (iii) a drive assembly connected to the rail and capable ofdriving the stop back and forth along the rail to different separationsfrom the site of action, and (iv) a controller programmed to controloperation of the motor; (B) entering into the controller a target valuefor a target dimension of a product to be generated from a workpiece;(C) causing the controller to operate the motor such that the stop isdriven to a target position spaced along the rail from the site ofaction according to the target value; and (D) modifying the workpiecewith the tool to generate the product, with the workpiece aligned withthe rail and disposed against the stop at the target position.

156. The method of paragraph 155, wherein the step of providing includesa step of mounting the rail on a frame for supporting the tool, andwherein the step of mounting is performed with one or more bracketassemblies, and wherein the one or more bracket assemblies include ashelf to support workpieces by contact with an underside of theworkpieces.

157. The method of paragraph 155 or 156, wherein the step of causingincludes a step of pressing a start button.

158. The method of paragraph 155 or 156, wherein the step of causingresults from the step of entering.

159. A method of processing a workpiece, comprising: (A) providing (1) atool to modify workpieces and having a site of action, and (2) apositioning apparatus connected to the tool and including (i) a railmodule including a beam and a first member connected rotatably to thebeam, (ii) a stop connected or connectable to the rail module such thatrotation of the first member drives the stop back and forth along thebeam, (iii) a power module including a motor and a second member drivento rotate by operation of the motor, and (iv) a controller incommunication with and programmed to control operation of the motor; (B)mating the power module with the rail module by fitting the first andsecond members together such that the operation of the motor transmitsmotive power to the first member; (C) entering into the controller atarget dimension of a product to be generated from the workpiece; (D)causing the controller to operate the motor such that the stop is drivento a target position spaced along the beam from the site of actionaccording to the target dimension; and (E) modifying the workpiece withthe tool to generate the product, with the workpiece aligned with thebeam and disposed against the stop at the target position.

160. The method of paragraph 159, wherein the step of mating includes astep of disposing a shaft in a socket.

161. The method of paragraph 160, wherein the step of mating includes astep of mating a shaft provided by the power module with a socketdefined by the rail module.

162. The method of any of paragraphs 159-161, wherein the step of matingis performed without the use of tools.

163. The method of any of paragraphs 159-162, wherein the beam defines alongitudinal axis, and wherein the step of mating brings the powermodule into mated engagement with the rail module by motion of the powermodule in a direction orthogonal to the longitudinal axis.

164. The method of any of paragraphs 159-163, wherein the rail moduleincludes a pair of pulleys rotatably mounted to the beam, and whereinthe step of mating is performed while both of the pulleys remain mountedto the beam.

165. The method of any of paragraphs 159-164, wherein the rail moduleincludes opposing left and right end regions, and wherein the drive unitis capable of mating alternatively with the rail module at each of theopposing end regions.

166. The method of any of paragraphs 159-165, wherein the step of matingcreates a mated connection of the power module to the rail module bybringing the power module and the rail module together along a matingaxis, wherein the mated connection permits separation of the drive unitfrom the rail unit by urging the power module and the rail module apartalong the mating axis, further comprising a step of attaching the powermodule to the rail module such that separation of the power module fromthe rail module along the mating axis is blocked.

167. The method of paragraph 166, wherein the step of attaching blocksrotation of a body of the power module with respect to the beam when themotor rotatably drives the mated connection.

168. The method of paragraph 167 or 168, wherein the step of attachingincludes a step of manually attaching the power module to the railmodule with a cam-based latch, without the use of tools.

169. The method of any of paragraphs 159-168, wherein the controller isincluded in the power module such that the step of mating connects thecontroller to the rail module.

170. The method of any of paragraphs 159-169, wherein the step of matingdisposes the first and second members in a meshed configuration.

171. A method of positioning a stop for workpiece processing, the methodcomprising: (A) receiving a target dimension of a product to begenerated from a workpiece using a tool having a site of action; (B)calculating a plurality of drive signal values to execute at least aportion of a drive sequence that drives the stop to a target positionspaced from the site of action of the tool according to the targetdimension, each drive signal value being associated with a measuredspeed of a motor that supplies motive power to the stop; and (C)supplying power to the motor according to the drive signal values,wherein each drive signal value that exceeds a predefined limit isreduced before such drive signal value is implemented to supply power tothe motor.

172. The method of paragraph 171, wherein the predefined limit increasesat least once as the measured speed increases.

173. The method of paragraph 171 or 172, wherein the predefined limitincreases linearly with the measured speed.

174. The method of any of paragraphs 171-173, further comprising a stepof receiving a slope value, wherein the predefined limit increaseslinearly according to the slope value.

175. The method of any of paragraphs 171-174, further comprising a stepof receiving a value for the predefined limit to be applied when themeasured motor speed is zero.

176. The method of any of paragraphs 171-175, wherein the at least aportion of the drive sequence is performed in a plurality of timesegments, and wherein the step of calculating includes a step ofcalculating a drive signal value for each time segment.

177. The method of any of paragraphs 171-176, wherein each drive signalvalue is set to the predefined limit for a measured speed associatedwith such drive signal value if such drive signal value exceeds thepredefined limit.

178. The method of any of paragraphs 171-177, wherein step of supplyingpower includes a step of supplying power by pulse width modulation.

179. The method of any of paragraphs 171-178, further comprising a stepof monitoring data from a sensor associated with the motor, determiningwhether the data meet a predefined condition indicating that the drivesequence is proceeding abnormally; and aborting execution of the drivesequence before the stop reaches the target position if the data meetthe predefined condition.

180. The method of paragraph 179, wherein the sensor is a rotaryencoder.

181. An article comprising at least one computer readable storage mediumcontaining instructions executable by a computer to perform any of themethods and/or any combination of the method steps set forth in thepresent disclosure.

The disclosure set forth above may encompass multiple distinctinventions with independent utility. Although each of these inventionshas been disclosed in its preferred form(s), the specific embodimentsthereof as disclosed and illustrated herein are not to be considered ina limiting sense, because numerous variations are possible. The subjectmatter of the inventions includes all novel and nonobvious combinationsand subcombinations of the various elements, features, functions, and/orproperties disclosed herein. The following claims particularly point outcertain combinations and subcombinations regarded as novel andnonobvious. Inventions embodied in other combinations andsubcombinations of features, functions, elements, and/or properties maybe claimed in applications claiming priority from this or a relatedapplication. Such claims, whether directed to a different invention orto the same invention, and whether broader, narrower, equal, ordifferent in scope to the original claims, also are regarded as includedwithin the subject matter of the inventions of the present disclosure.

We claim:
 1. An apparatus for linear positioning of workpieces,comprising: a fence module including a rail defining a long axis, andalso including a first coupling member mounted in the rail on a rotationaxis that is orthogonal to the long axis; a stop connected orconnectable to the fence module such that rotation of the first couplingmember about the rotation axis drives the stop along a travel pathparallel to the long axis; a power module including a motor and a secondcoupling member, the first and second coupling members havingcomplementary structures configured to become meshed with one anotherwhen the coupling members are mated with one another parallel to therotation axis, such that rotation of the second coupling member, drivenby the motor, is coupled to rotation of the first coupling member aboutthe rotation axis; and a controller programmed to receive a set pointthat corresponds to a position in the travel path and to control themotor to drive the stop such that the stop halts at the position.
 2. Theapparatus of claim 1, wherein the first coupling member is a pulleydefining an opening, and wherein the second coupling member is a splinedshaft that is configured to be received in the opening such thatcomplementary structures of the splined shaft and the opening of thepulley mesh with one another.
 3. The apparatus of claim 2, wherein thepulley is a first pulley and the rotation axis is a first rotation axis,wherein the fence module includes a second pulley mounted in the rail ona second rotation axis, and wherein the fence module also includes abelt that couples rotation of the first and second pulleys to oneanother.
 4. The apparatus of claim 1, wherein the power module includesthe controller and is configured to be mated with the fence module as aunit.
 5. The apparatus of claim 1, wherein the rail defines a pair oflongitudinal channels, and wherein the power module includes a pair ofjaws configured to be received in the pair of longitudinal channels. 6.An apparatus for linear positioning of workpieces, comprising: a fencemodule including a rail defining a long axis, and a first couplingmember mounted in the rail on a rotation axis that is orthogonal to thelong axis; a stop connected or connectable to the fence module such thatrotation of the first coupling member about the rotation axis drives thestop along a travel path parallel to the long axis; a power moduleincluding a motor and a second coupling member, the power module beingconfigured to be mated, as a unit, with the fence module, as a unit,while the first coupling member remains mounted in the rail on therotation axis, such that complementary structures of the first andsecond coupling members become meshed with one another, thereby couplingrotation of the second coupling member, driven by the motor, to rotationof the first coupling member about the rotation axis; and a controllerprogrammed to receive a set point that corresponds to a position in thetravel path and to control the motor to drive the stop such that thestop halts at the position.
 7. The apparatus of claim 6, wherein thefirst coupling member is a pulley defining an opening, and wherein thesecond coupling member is a splined shaft that is configured to bereceived in the opening such that complementary structures of thesplined shaft and the opening of the pulley mesh with one another. 8.The apparatus of claim 6, wherein the power module includes thecontroller and a user interface for the controller.
 9. The apparatus ofclaim 6, wherein the rail defines a pair of longitudinal channels, andwherein the power module includes a pair of jaws configured to bereceived in the pair of longitudinal channels.
 10. A gauge system forworkpiece processing using a tool having a site of action, comprising: afence module including a rail defining a long axis, and a first couplingmember mounted in the rail on a rotation axis that is orthogonal to thelong axis; a stop connected or connectable to the fence module andconfigured to be abutted with an end of a workpiece; and a power moduleincluding a motor, a second coupling member, and a controller, the motorand the controller being substantially contained by a same housing,wherein the power module is configured to be mated, as a unit, with thefence module, as a unit, along a vertical axis from above the rail whilethe first coupling member remains mounted in the rail on the rotationaxis, such that complementary structures of the first and secondcoupling members become meshed with one another, thereby couplingrotation of the second coupling member, driven by the motor, to rotationof the first coupling member about the rotation axis, and wherein thecontroller is programmed (i) to receive and/or calculate a targetdimension of a product to be generated from the workpiece with the tooland (ii) to control operation of the motor such that the stop is drivento a target position spaced from the site of action according to thetarget dimension, thereby allowing the workpiece abutted with the stopto be modified by the tool to generate the product.
 11. The gauge systemof claim 10, wherein the tool is a miter saw defining a cutting path,wherein the stop is driven back and forth along a linear measurementaxis that intersects the cutting path to define an origin, and whereinthe controller is programmed (i) to receive a width and a targetdimension of a product to be generated from the workpiece, and (ii) tocontrol operation of the motor based on the width and the targetdimension such that the stop is driven to an adjusted position spacedfrom the origin by an adjusted dimension produced at least in part bymodifying the target dimension with at least one miter offset, tocompensate for a miter at one or both ends of the product.
 12. The gaugesystem of claim 10, wherein the first coupling member is a first pulley,wherein the fence module includes a second pulley and a belt thatcouples rotation of the first and second pulleys to one another, andwherein each of the pulleys is mounted in the rail for rotation about arespective rotation axis.
 13. The gauge system of claim 12, wherein thepulleys are configured to remain mounted in the rail on the respectiverotation axes, as the power module is being mated with either of thepulleys along a vertical axis.
 14. The gauge system of claim 10, furthercomprising a travel barrier connected to the rail, wherein the stop hasa range of travel along the rail, wherein at least one end of the rangeof travel is determined by the travel barrier, and wherein thecontroller is programmed, if a current location of the stop within thetravel path is not certain, to drive the stop until movement of the stopis halted by the travel barrier, thereby defining the current locationof the stop.
 15. The gauge system of claim 10, further comprising acarriage configured to connect the fence module to the stop, wherein therail supports the carriage and forms a pair of longitudinal channels onopposite lateral sides of the rail, and wherein the carriage is drivenalong the rail guided by the pair of longitudinal channels.
 16. Thegauge system of claim 10, wherein operation of the motor holds the stopat the target position.
 17. The gauge system of claim 10, wherein thecontroller is programmed (i) to receive an input that indicates whetherthe tool has a leftward position or a rightward position with respect tothe rail and (ii) to select rotational directions for operation of themotor that drive the stop toward and away from the tool based on whethera leftward or rightward position is indicated by the input.
 18. Thegauge system of claim 10, wherein the power module includes a graspablehandle located opposite the second coupling member.
 19. The gauge systemof claim 18, wherein the handle is located at or near a top of the powermodule.